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Baja 250, No Spark , I'm stumped ...

Mhatayas
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Mhatayas Apprentice

Mhatayas

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My uncle bought a Baja 250, 2006. Knew there was no spark since the get go. He don't know anything about quads so is getting me to help him try to get it running...

 

battery is bad so I connected battery charger to it to crank it over , cranks over well , but no spark .... 

Lights and everything work fine , but with each crank over using the e start switch , the display reads 999 888 777 666 ... Right down to 000 and repeats itself . 

 

He managed to get a parts bike , I changed over the CDI and the coil and the stator from the parts bike and there was another black box by the voltage regulator I changed over ... I used my multimeter to confirm as much as I could works , it's hard without knowing which wires are which , and I cannot find any diagrams online for this bike ? 

 

Do you think it could be the Killswitch? There's so many wires coming from there I don't know where to start . Also I should mention it appears the fan on the front of the bike has been taken off (the wires have been cut too ) 

 

If this bike sparked it would run . The previous owner said he parked it one day and it just wouldn't start after.

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Mech Grand Master

Mech

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You need a battery too. That dash display going screwy is because the voltage is dropping too low when you are using the starter. The charger isn't supplying enough power to run the starter.

If it cranks too slow because of not enough battery power then it might not make spark, and if the cdi uses 12v it won't work at the very moment it needs to, just as the piston's coming up on compression stroke and the dash dies.

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Mhatayas Apprentice

Mhatayas

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I had the battery charger set to 20amps , it seemed to crank over fine but the display still spazzed out . So just yesterday I found 2 potential reasons why there were no spark . A blue wire coming from the stator that connects to the CDI , one of the connector pins was pushed back . I fixed it with some needlenose plyers , and the next thing I did was check for resistance between the coil and the plug cap with multimeter. One didn't have any resistance and the other did have resistance, so I put it back together, and wait a go ! Spark . Put a small bit of fuel in the piston just to hear it start up . I now drained the gas as there was water in there ,next I'm gonna clean the carb up before I actually take it for a run ! 

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Mech Grand Master

Mech

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Good work finding the pushed back pin..

Time after time it's the wires not the electronic bits.. or Switches.. That flickering could be a key switch, or perhaps the kill switch, with dirty contacts. I'm pretty sure the flickering will be because the voltage to the gauge is dropping below the about 5volts the internals of the gauge usually work on.

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