Another electrical problem, really??

[shorty]

So now this "new to me" Kowhockey has ANOTHER problem. Replacing the rectifier cured the charging problem, rode around for a while, Yahoo!.. but this morning it wouldn't start, hmm 🤔 checking for spark, nuttin.. CDI igniter module bad. It's not the coil because when the key is turned off the spark knocks me down. Glad I got this old quad cheap because I'm replacing lots of electrical parts. Also found 3 blown fuses in the toolkit. 😭

[bigfatkahuna]

Dang man! That's frustrating! I think electrical issues are most home mechanics biggest bane.

Good luck!

[jen]

Use your Fluke meter to check DC amps when machine is off.

[jen]

Multi pin connectors are usually suspect when you see  amps when unit is off...0.05 +-amps probably tolerable. Pulling fuses to reduce /eliminate current is an easy check.   Howeve,  Multi pin connectors will short out one pin to another and cause bat drain

[shorty]

Thanks for the replies friends. Waiting for the new CDI module now.

Edited August 14, 2025 by shorty

[jen]

BTW Tie Wraps on high VDC ignition leads are bad.  Many times guys will 'hog down' on tie wraps pulling the wire tight to metal (its grounded) housing.

[shorty]

Thanks Jen 

[shorty]

I purchased the CDI module through Amazon for only $22 but it's not OEM. It's made in China with Free returns. The waiting is eating up the riding season 

[jen]

On industrial controls high voltage igniter wires laying pressed tight to metal  would cause control relay chatter on 120 vac circuits and play hell with low voltage  circuits  and frequency controllers.

You got to love it   ...it's like a murder mystery!

[shorty]

Like bigfatkahuna said, we don't really enjoy electrical problems 

[jen]

BTW I will mention it however, I am sure you guys know this but others may not. Do not use water-soluble flux when soldering cu wires.  Water-soluble flux will corrode the wires to dust.

[jen]

And while I am venting on pet peeves....When trouble shooting one of the first things is "Tug And Pull "  No I am not talking about my hair. I've been around enough construction sites  to know how men's minds function.....LOL but tug  pull wire terminations. 

Next look for unstripped wires at terminals. when the plastic is under the terminal  you will get no connectivity or worse yet intermittent connectivity.  Screw terminals for landing wires is the best (Point to point wiring).  I absolutely hate "Punch down Terminal blocks".  ( The wire is unstripped and placed over 'V' block and then punched into the V...😡  

[shorty]

I also noticed the lead free solder is slightly corrosive. I don't mean acidic flux, even the rosin core lead free stuff seems corrosive 

[jen]

Yeah if is made for plumbers it's no good.