XXDEF1ANTXX Posted August 7, 2018 Report Share Posted August 7, 2018 Hey gang, not sure if the forums are still as active as they were before FB came along but I figured I would try anyways, so here goes. I recently picked up a basket case for a good price and the PO said it had issues with spark, so being pretty ok with electrical stuff as I completely wired my XR650R and learned a great deal while doing. Anyways, I get the quad home and immediately start tinkering and I find the tors box still connected yet all the tors stuff was deleted. I unhooked it and bam it sparked. Then in the process of trying to start it and tune it I found a air leak in the crank seal and a few other issues so I tore down the engine and did a complete rebuild. I got it all back together and crank it over and I had it running and began tuning it, this is where my issues started. I removed the carbs to install bigger pilots and it wouldn't start, so I began with checking for spark and there was none. I tested the coil and the primary tested within spec and I tested the secondary as the clymers says and nothing, I check resistance accross both boots and it was within the clymers specs, interesting. I then checked the stator and all of that, except the lighting coil, tested within spec. I then checked all wires for continuity and they all checked out (there is no key switch, so the red/black was tied directly into ground as it should be). I tested the kill switch and it didnt show continuity on or off, so I took it apart and cleaned the contacts, so that is fixed now. I then checked all my grounds and even added a grounding strap from a head stud to one of the coil mounts just to make sure the motor had a good chassis ground. I also checked the pickup gap and set it to .016". Heres where it gets interesting, I checked the voltage output from the stator ignition coil and it would read between 5-8 volts (between red and green at the stator plug) and then I read the voltage output from the CDI at the coil plugs and it only read .4 volts. After seeing that, and knowing that the capacitor within the CDI should be putting out more than its getting in I figured my CDI was shot. After all that, I ordered a used OEM CDI, a used OEM Coil, and a new RS Stator (was checked by F.A.S.T. before shipment) and I hooked it all up and still no spark. The stator and coil checked good as far as Ohm readings go and I have yet to check the CDI voltage output to the coil. I also tore apart the harness and checked wires for damage and found the harness was in good shape and I rechecked and made sure to sand clean all the paint from chassis ground locations. Sorry for the long post but in an effort to be thorough and paint a complete picture of my issues it needed to be this long. Can anyone point me in the right direction on what to try next? Unfortunately I dont have anyway to swap parts from a known running banshee as I dont know anyone locally who has one. I am at my wits end trying to figure this thing out, and I find it highly unlikely that I received 1 or more DOA components. Quote Link to comment Share on other sites More sharing options...
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