Young Guns Racing Posted June 30, 2013 Report Posted June 30, 2013 Ok, longer story short I put together a mostly stock engine to take to a dirt drag event that ended up getting rained out. So today I took the engine out of my frame and installed it into the frame it belongs in so I can sell the bike. Engine ran perfect, no hiccups, plenty of power and so on. I was very happy. After the install I get an intermitant spark through my plugs and the engine will not start. It only sparks once or twice at random intervals and thus this cant run the engine. I changed the stator over because the frame I had it in was the square plug, this frame was the round plug harness. When I swapped them over I noticed the RH mount for the pickup module had jb weld on it - go figure - looks very straight but apparantly it was broken at some point. Anyhow I am not new to trouble shooting but new to an issue like this. Any ideas on where to start? Thanks for reading. Quote
375hp banshees Posted June 30, 2013 Report Posted June 30, 2013 (edited) it was in this frame to start with...it ran fine in 2nd frame, then put it back in the 1st frame ...where did the stator swap come into play & did this stator work before what is you pick up gaped at? Edited June 30, 2013 by 375hp banshees Quote
375hp banshees Posted June 30, 2013 Report Posted June 30, 2013 (edited) it's not a red Jframe w/ yellow plastic & troy lee design stickers shee is it? Edited June 30, 2013 by 375hp banshees Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 no it isnt. Its just a red and white bike with a black frame. Pickup is gapped at .018 The stator I suspect giving me issues was on the bike originally. Had a bad crank bearing. So I removed it and had a good bottom end already built. So i pulled the top end from the original bad crank motor, as well as all the components to make it run, and swapped them into a whole nother silver frame which is my personal bike (not a sale prospect like the red bike). I swapped it into that frame because its engine is nowhere near finished and I wanted to race banshee stock class at a local drag event - this is where the stator swap occured, I changed it to fit the wiring harness of the silver frame. The engine worked and ran fine. Drags got rained out and so now I am switching it back into the frame it belongs in. So I put the original stator back onto it and now I have the intermittent spark I hope that helps clarify. I am going perform some ohms tests and continuity checks this morning and see if anything turns up. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 (edited) Well heres an update. Everything checked out the OHMs and continuity tests. The signal to the orange wire on my coil is still intermittent and Im not sure why or where the issue comes from. The orange wire has great continuity from the CDI. Im going to keep at it. Any advice would be great. Thanks. Edited June 30, 2013 by JohnnyBoy1986 Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 Just swapped stator assembly over. I had a new style and made a jumper harness to plug it in. Still intermittent spark, no go. This sh*t is getting very frustrating very fast lol I dont see why the unit just wont go. Any help at any time will be appreciated. The TORS system is eliminated, there is no parking brake system. Im at a loss so far. Quote
hoppedupandcutdown Posted June 30, 2013 Report Posted June 30, 2013 Had a guy on here that had corrosion in the harness where all the ground wires split off. rear of where the lighting bullet connectors are. 1 wire splits to 5 i think. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 Had a guy on here that had corrosion in the harness where all the ground wires split off. rear of where the lighting bullet connectors are. 1 wire splits to 5 i think. I will check. I am in the process of uploading a video on youtube to show what i have going on. Thanks. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 Here's the video of the test light showing the signal from CDI to the coil. You'll see sometimes its a "bright" flash, those are multiples, low flashes are singles. Sorry for the quality. I had to hold my phone and kick at the same time. I hope this helps. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 I am leaning towards a CDI now. The grounds were good, I opened the entire harness, continuity is good everywhere. No reason this thing shouldnt have constant spark. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 Just made a jumper harness and tried my CDI from my running bike. Still no good. Still F******g intermittent signal and spark. Now I am completely lost. What the hell is going on? Id love to see some advice at this point. Quote
Young Guns Racing Posted June 30, 2013 Author Report Posted June 30, 2013 WOW well it is SOLVED!!!! Would you believe it if I said it was the key switch? I tested it at least twice and it worked both times. I got to the end of my wits and seeing as the ignition system is not all that complicated I gave it one last go, I jumped the switch and boom! she sparked constantly and so I hooked things up and kicked - first time over she fired and ran beautiful. It was ridiculous lol. Anyhow I appreciate all the help and people reading. I hope this thread may give others hope for these situations, just keep at it. Quote
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