350x No Spark

[jaykup]

I'm trying to solve my sparking problem for this weekend. Last time I had it out, about 6 months ago it started and ran normally. Now I tried to start it and nothing, not even a pop. When I checked the plug, it was not getting any spark.

Using a volt meter, I checked the following components:

Spark Plug - New
Coil - Tested bad, replaced with an aftermarket new one
Spark Plug Boot - Still same old one, but seems to have a nice connection
Voltage Regulator - Tested bad, replaced with an aftermarket new one from Howdy
CDI - Unknown status

Now comes the part I'm having problems with.
The three plugs that come off the stator wire tested as follows

White plug - 0 ohms between terminals
Red Plug - Infinite ohms between terminals, 0 ohms between either terminal and ground
White/Black single plug - 0 ohms from ground to plug.

I have two stator cover assemblies. One that was always on the bike, and another I just bought on eBay, that was claimed to come from a running bike. Both stator cover assemblies tested the same. The eBay one looks like it was rewound.

The manual calls for like 300 some ohms on some of those connections, but I don't really understand what all the parts do -- Exciter coil, Lighting Coil (just powers lights I'm sure), pulse generator, etc.

Can someone help explain the testing procedure for those 3 plugs and what component is bad, if that is even the problem? The only other thing I've gathered from the forums on this, is that some of the wires may be shorting to ground?

I am hoping I can get this solved in the next few days so I can give it a proper shake down on the trails.

[Erics350x]

are you sure you don't have a bad ground or a wire shorting out? Sounds odd that the coil and regulator would be bad at the same time and you still dont have spark

[Itrike]

Try taking youre swithes off the bars just let them hang then check for spark

[jaykup]

are you sure you don't have a bad ground or a wire shorting out? Sounds odd that the coil and regulator would be bad at the same time and you still dont have spark

This seems like my next step, maybe a wire is touching the ground somewhere


Try taking youre swithes off the bars just let them hang then check for spark

I have the switch apart with the terminals connected manually, to ensure the switch was not the problem.

How does my stator/pulse generator tests all look?

[SWIGIN]

i would unplug the kill switch from the harness all together......this way is will have spark all the time ( or should if it was working)with no chance of it being the switch

[jaykup]

i would unplug the kill switch from the harness all together......this way is will have spark all the time ( or should if it was working)with no chance of it being the switch

Oh.... maybe I've been doing this wrong? When the kill switch is closed then there is no spark... When it is open, there should be a spark. I thought it was the other way for some reason.

Crap. I'll check it tonight.

[Erics350x]

^there's your problem^

[jaykup]

Yup, I'm an idiot.

But after I disconnected it, still no spark. I unplugged the CDI box and checked the wires in the wiring harness with an ohm meter. Everything seemed good. Made sure all the connections were clean, put it all back together, with the kill switch unplugged, and finally.. it sparked! A nice healthy blue spark.

Must have been a combination of the closed kill switch and the connections to the CDI box.

Thanks for the help!