Warrior spark issue

[Warrior 350]

Ok I got a warrior 350 when the key is off I get spark but if key is on no spark any help with this would be helpful

[Frank Angerano]

Welcome to Quadcrazy, is the ignition switch new? Replacement?  Maybe damaged? I would take it out and inspect the switch as well as any crossed wires.  See if someone removed the plug and maybe hardwired it ?

[Warrior 350]

Yes brand new switch un hooked it to see if I got spark and nothing if it's in the on position won't get fire if I shut it off and pull start it fires up but stutters I'm at a loss

Edited February 23, 2018 by Warrior 350

[Frank Angerano]

It sounds like something is back feeding power into the ignition circuit somehow. Maybe an accessory? Plow lights of some sort ? I would get a tester and see what wire gets power at the ignition plug when you turn  the ignition off and trace that back.  Also check the entire harness for damage. Wires get hit all the time or areas where the harness is rubbing against the frame of the bike wear away the tape and insulation. After that i would start checking the stator coil, regulator, and secondary coil with a tester for proper ohms that’s shown in the repair manual. If you are not sure how do do that we can kinda walk you through it or check on YouTube as well it’s very helpful   

 

[Warrior 350]

Thank I'm replacing the harness cdi stator coil and regulator a buddy has a parts warrior so gonna try that 

[Cj Winds]

The new ignition switch is wrong switch. This just happened to me. I bought the cheap $10 one on ebay or amazon. The correct switch should be normally open on both circuits where as the cheap new one I bought is normally open on one circuit and normally closed on the other (which is the way many other atv ignition switches work). One circuit is to turn positive battery power on and off, the other circuit is a ground wire for the CDI. I corrected the issue by connecting the two wires for the CDI circuit. The ignition switch is now only used to turn on and off battery power, it does not kill the engine. The only way to kill the engine now is to use the kill switch. 

[Frank Angerano]

Makes sense 

[Warrior 350]

I appreciate the help guys I ordered new parts just waiting on them to get here someone before hacked the wiring harness so I bought different one along with a factory ignition stator and cdi hoping I can get it going

[Cj Winds]

The only part you need is a OEM ignition switch.

On mine, all I did was hack into the wiring thats part of the faulty ignition switch, I did not hack into the atv wiring harness

If you are really good with switches, you can try to disassemble and clean the switch, usually its just the contacts that get corroded or dirty. My switch showed 150 ohms of resistance on the cdi side when it should be under 1 ohm

Or if you want to be getto, you could use two seperate switches. Use the old switch if it still has a one good circuit and the new switch for the other circuit

[Warrior 350]

The guy I got it from had hacked the wiring harness at the stator thus why I bought a harness and new cdi and stator

[Warrior 350]

On changed stator and keyswitch with a oem one and still no spark and can't find a cdi for my 87 warrior any input guys and can a cdi be tested

[Cj Winds]

Cant test CDI, need to test everything else before you can suspect CDI, you can replace CDI with known good one. CDI is under the front body plastics, inbetween and above front tires...I think

 

[Warrior 350]

Ya I had my buddy test everything else on it and put the cdi on his and his didn't have any spark either so figured it was shot his works and I get spark but he rides his often so can't take his lol

[Warrior 350]

Ok guys I replaced stator cdi and key switch with oem key switch and still only gets fire with key in off position

[Frank Angerano]

Was the stator an oem ?

[Frank Angerano]

Sorry the cdi I meant***

[Warrior 350]

Yes it's oem works good if key is off can't find any other for it cause it is a 87 only model it's all oem key stator and cdi 

[Cj Winds]

What year is your machine?

[Warrior 350]

It's a 1987 from what I hear they are a pain in the but 

[Cj Winds]

Do you have a multimeter? measure resistance on main switch, black to black/red, and red to brown. Both should have continuity when switch is on and no continuity when switch is off

[Warrior 350]

No but I can go get one

[Warrior 350]

And another thing I noticed when the key is off it's easy to pull but turn it on and it's harder like there is resistance

[Warrior 350]

Ok got it running but issue is the reverse and neutral light are on at the same time and when I try to put it in reverse it dies and no reverse at all on it got a spare motor I was going to swap but wanted some input first

[Cj Winds]

Does the engine die when you put it in forward gear?

[Warrior 350]

Nope just reverse as soon as I put it in it dies

[davefrombc]

My guess is there is a problem  between the reverse switch that  turns on your reverse  light  and the  neutral  safety switch. I think you might find that  light grounding through the  neutral  safety  switch  and  killing the  engine. I would  look for  the  wires  shorted  or possibly  misconnected.

 

[Warrior 350]

Ya getting ready to check it all out and see y it don't go in reverse

[Warrior 350]

Well got it figured out they had the wrong reverse switch in it took one off my other warrior parts motor and fixed it now to tune carb and it's all good

VID_20180307_143737.mp4