1998 Kawasaki Bayou wiring help

[Andrew Baker 0]

Should I be getting continuity between the 2 pickup wires? I do on all my other vehicles but not this one. Maybe bad pickup?

 

[Frank Angerano 837]

If it’s new it should be fine. What you should get is a reading on ohms setting, if not then there is a problem. 

I am looking at diagrams for you.  I will be in touch.   

[Andrew Baker 0]

It is not new. If fact, I think it is the original 1998 coil. I'm getting no more that 15.8 ohms of resistance. Should it not be more like 130 to 150? That's what it is on my buggy. But that is a1 50cc GY6.

[Frank Angerano 837]

Sorry it took so long I’m up hunting and it’s hard to get a good signal up here and the time to look. 
Attached is a page for the ranges of all the coils etc.   Also all the diagrams I could find. It’s about 6 of them and because you don’t know exactly what bike it is yours is then your going to have to compare each diagram until you find a match.   
Can you see the vin number clearly ? If so then post it. Maybe we can find out more.  

[Andrew Baker 0]

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue?

 

[Frank Angerano 837]

Absolutely 

The new stator will or should come with the pick up coil as well.   
Stators go bad from a few different things but mainly from trying to jump the bike with a car or welding on the frame without disconnecting the stator and installing the battery wires backwards.  

[Andrew Baker 0]

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue? I'm getting 0.7 ohms of resistance between the yellow wires from the stator. 

 

[Frank Angerano 837]

Check each wire from the stator to the ground on continuity and see if you get a reading. One lead of the tester on one of the yellow wires and the the other lead of the tester to a good ground.  If you get any kind of a reading on continuity or ohms then there is a problem with the stator.  As far as the 0.7 I would have to see what the specifications for that atv call for. But do that test first and see what happens.  

[Andrew Baker 0]

All open line and no continuity. I'm so stumped. Now I will say that I do not have the starter relay on it. It is still in the mail. But I do have the white wire that goes to the relay hooked straight to the positive side of the battery

 

[Frank Angerano 837]

That white wire on the positive should send voltage to the harness.  Have you checked that it’s going through the ignition and feeding the brown ?

[Andrew Baker 0]

My headlights work. Should I check somewhere else?

 

Also, my indicator lights work. 

Edited November 25, 2019 by Andrew Baker

[Andrew Baker 0]

[Frank Angerano 837]

That plug is an accessory connector of some sort maybe a battery tender. If you look at a lot of the wiring diagrams it shown an accessory set of wires.  Check it for voltage with key on and off.   
Was it plugged into anything  or is it just hanging.  

[Andrew Baker 0]

Just hanging. I thought maybe the red recharged the battery. It looks to me like the battery get recharged via the white wire. Is this correct?

 

*EDIT* I see the terminals in one of the diagrams I have. I just missed because in my diagram it is toward the front of the vehicle.

Edited November 26, 2019 by Andrew Baker

[Frank Angerano 837]

Yep it’s prob an accessory terminal or charging port.  

I just looked at the diagram it is an accessory/trailer lights terminal. 

[Andrew Baker 0]

Well then I'm still without spark. So, I know my pickup coil was bad. I happened to have one from a CN250 (GY6 style) that looked the same so I used it. I'm thinking maybe it just isn't working with that engine. I don't know what else it could be. I'm getting headlight, and indicator lights. My CDI should be good because I pulled one off of a Bayou 250 just one year newer. Same with the rectifier. I'm starting to dislike this ATV.....

[Frank Angerano 837]

I would start to pull the harness away from the frame and start to check for any cuts or broken wires.  

Then 
Start  checking continuity from one end of a wire in the harness to another. So locate  a brown wire and start checking for another brown wires and check continuity at each spot. 
Do the  same for all wires in the harness to make sure they are not broke.  
Understand or am I not clear? 
 

[Andrew Baker 0]

Perfectly clear. I'm mostly frustrated because I'm not used to having issues like this lol. I'm no bewbie to wiring at all. I have built several GY6 and CN250 builds and built custom harnesses by hand, as well as build several Honda's for racing and custom built those harnesses as well. So, in theory, this should have been a breeze. 

[Frank Angerano 837]

Been down this road a few times. I have come across more then a few pain in the asses.  
Now it becomes an obsession figuring this out.  And I want to know what the final result was so let’s see this through for the next member that has this problem.   
Somethings grounding this circuit out or it’s a bad cdi. 
 

[Andrew Baker 0]

Well, I now have spark! But only pull start. I hooked up my starter relay and tested it. It works, but nothing from the push button. I took it apart and cleaned the contacts. I get no continuity with the button unpressed and continuity when pressed so to me that means the button it good. Could this be a starter circuit relay issue?