glyph Posted August 24, 2007 Report Share Posted August 24, 2007 Hi all My other post was becoming a little off topic so thought I'd start a new one. Basically, I've got no spark at the plug. It's got a brand spanking stator on it, I've cleaned the plug, checked for splits in the wires, checked the cut out switch, cleaned up the terminals on the coil, so no my next best bet is the CDI right? Wrong? Any other suggestions? Am I correct in thinking it will still run with this connector block disconnected? Obviously, I'll have a hard time stopping the engine, but for the time being I'm just after a spark. Much appreciated Glyn Quote Link to comment Share on other sites More sharing options...
glyph Posted August 24, 2007 Author Report Share Posted August 24, 2007 Can anybody tell me please if this should produce a spark?: Also, the wiring diagrams I have are for a later model and appear to be different. Can anybody tell me also what the loose black and yellow wires are coming from the stator? Muchos gracias Quote Link to comment Share on other sites More sharing options...
stork955 Posted August 24, 2007 Report Share Posted August 24, 2007 Can anybody tell me please if this should produce a spark?: (Picture ) Also, the wiring diagrams I have are for a later model and appear to be different. Can anybody tell me also what the loose black and yellow wires are coming from the stator? That should work. Sorry I cant tell what the extra wires do, they dont seem to be in a wiring diagram. Do you have a volt meter handy? Cheers, Stork. Quote Link to comment Share on other sites More sharing options...
stork955 Posted August 24, 2007 Report Share Posted August 24, 2007 Just had another look, the yellow drives the horn, the black goes to the CDI via a seperate wire (on a early rev 3 anyway) your bike doesnt appear to have that. Cheers Stork. Quote Link to comment Share on other sites More sharing options...
glyph Posted August 24, 2007 Author Report Share Posted August 24, 2007 Thanks that for that. Although this does present a problem. Where do the cut out switch and fan connect to? I have a multimeter to hand and have checked the continuity of the HT lead but wouldn't know where to start with the other components. Does anybody have a wiring diagram for the 2000 model they could send me please? Just ordered a new CDI, which I think has been the route of all my evils. This has been a very expensive learning curve. Quote Link to comment Share on other sites More sharing options...
stork955 Posted August 24, 2007 Report Share Posted August 24, 2007 I can send you the manual I have, its 897kb so pretty small. Checking the coil is easy, with a new stator thats most likely the problem you have. (CDI's are pretty bulletproof generally.) With an ohm meter check the coil primary resistance - between the small wires going in if you have two of them, or between the single wire and the frame of the coil if only one. You should see around 2 to 5 ohms. The secondary side should see around 5k - 20k depending with the plug cap on. These numbers arent too critical as Coils usually go open circuit so if this was the case you would read very high. You can also check the stator with a volt meter. The source coil should provide above 50 volts AC kicking, 90 or more running. The wiring diagram doesnt distinguish between the source, lighting and triggers though, you would have to look at the actual stator to tell. HTH, Stork. Quote Link to comment Share on other sites More sharing options...
mikee Posted August 24, 2007 Report Share Posted August 24, 2007 I Quote Link to comment Share on other sites More sharing options...
bilco Posted August 24, 2007 Report Share Posted August 24, 2007 Ever thought of taking up a diffrent sport Glyph. just a thought. Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 25, 2007 Report Share Posted August 25, 2007 Just thought the coil usually grounds to the frame when bolted in. And the wiring harness to the switch and lights had three yellow wires that had to be connected, though could have been for the fan only. I would get rid of all the extra wiring for the lights etc. to remove all weak ponts of the system. Quote Link to comment Share on other sites More sharing options...
blocky Posted August 25, 2007 Report Share Posted August 25, 2007 Can anybody tell me please if this should produce a spark?: Also, the wiring diagrams I have are for a later model and appear to be different. Can anybody tell me also what the loose black and yellow wires are coming from the stator? Muchos gracias Highly unlikely I would say. The only part that I can see in the photo that has been grounded to earth is the spark plug. Most if not all of the other components will also use earth return to complete a circuit. Quote Link to comment Share on other sites More sharing options...
betarick Posted August 25, 2007 Report Share Posted August 25, 2007 The coil needs to be earthed by the wire with the loop that is normally earthed with the bolt that holds coil to the frame! Had the same problems as you before on my mates 04 270 ex dibbs bike! got a new stator and cdi from lampkins fiited stator first and still no spark! stuck cdi on and it fired up straight away! luckily lampkins let me bring stator back and just paid for cdi! Quote Link to comment Share on other sites More sharing options...
glyph Posted August 26, 2007 Author Report Share Posted August 26, 2007 I Quote Link to comment Share on other sites More sharing options...
neonsurge Posted August 26, 2007 Report Share Posted August 26, 2007 I've been watching this discussion with great interest - I've nothing useful to add apart from to say that I totally understand how you feel Glyph. I'm in the middle of a similar process with a Honda CRM250 enduro bike and for me, it's not the end result that matters, it's the experience and knowledge gained during the process and from looking at your web site, I bet you've learned a helluva lot! A complete rebuild? Wow dude, there's not many people who would attempt such major surgery with (I think it's fair to say?) pretty limited previous mechanical experience. I know I wouldn't - the engine from my old '03 Rev3 got boxed up and sent off to a specialist when it required a rebuild and new main bearings. TOTAL respect due and I look forward to seeing the riding pics once your bike is fully functional again! Quote Link to comment Share on other sites More sharing options...
beta bodger Posted August 26, 2007 Report Share Posted August 26, 2007 here here neonsurge! I too am inspired by Glyph's "give it a go" attitude. I guess im in for a steep learning curve myself soon. Quote Link to comment Share on other sites More sharing options...
bilco Posted August 26, 2007 Report Share Posted August 26, 2007 It's ok glyph i have a crap sense of humour. Put the electric's back on the bike how it should be,see if you can find someone to lend you a cdi unit and try that.If still no luck,the new stator might even be duff,also pull the kill button plug out and see what happen's. remember you don't fully know your bike untill you've had it all in piece's. Be lucky. Quote Link to comment Share on other sites More sharing options...
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