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By Eric C
I have looked at every thread I feel like, but with no resolution. Its always the same with a no spark issue:
Replaced CDI,
Replaced Pickup Coil (Pulsar)
Good continuity from CDI to green white wire at ignition coil.
No Pulse at ignition coil on the green white wire. (testing with test light on Pos of battery.)
Good 12+ V on the hot side of ignition coil.
I swapped the wires around on the Pulsar.
The grounds seem to be good for the blk/y wires throughout bike.
Brand new battery.
Brand new stator and Pulsar
Tried 2 new CDIs
Brand new rectifier
I get about 300 Micro A/C volts across the two wires on Pulsar when cranking.
I am currently cleaning the connections on the rectifier because they were burnt. I am not even sure if it makes a difference because I am told that doesn't produce spark anyway and is only for charging system.
The fly wheel looks OK, is the pulsar supposed to be connected in the direction with the metal "Button" facing towards the flywheel?
My bike is a 1995 bayou 300, but I seem to come across same issues on web but no resolution on these things.
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By SnowmanTX
Hello!
First time poster here, looking for help. This will be long, but I want to give you the whole story. I'm very confused because I am a fairly experienced mechanic but must be missing something. A friend who is not mechanical brought me a 2003 Eiger 400 automatic that didn't run. A quick inspection revealed that the motor was seized. I pulled the top end and found the cylinder and piston rings were rusted together from the machine having been submerged at some point and then left to sit for several years.
I put in a new piston and cylinder and checked the valve lash. Compression test today was 150 psi. Replaced the corroded vacuum petcock with a Yamaha petcock, cleaned the fuel tank out, and replaced all the fuel lines. Replaced the badly corroded carburetor with an Amazon aftermarket model (with good reviews) and it wouldn't start. Found that there was no spark so I substituted an Amazon 4-pin CDI box and found that I now have good spark. It still wouldn't start so I used a little starting fluid and it fired right up for about 3 seconds.
Now, after cleaning and checking out the new carburetor, I have found that when it cranks and fires, the engine actually kicks backwards momentarily and then resumes cranking. It is acting like the spark is way advanced and it is firing before TDC. I know that it is turning backwards momentarily because I still have the recoil off and I can see the starter cup rotating and then literally stopping momentarily when it fires. I've had the flywheel off to check the magnets and the woodruff key. The flywheel does not have the exposed magnets, but the fully enclosed magnets like the replacement RMStator flywheel. The woodruff key was in perfect condition. The pickup coil resistance test was good.
Since it seems like a timing issue, I pulled the cylinder head off again and double-checked the timing. It did appear that the timing marks were off by one tooth, so I corrected that and thought that I had found the problem. Unfortunately, it still does the same thing...It will crank just fine, but won’t start, and kicks backwards when it fires whether I use starting fluid or not.
Since the timing is not adjustable on this machine, I’m wondering if the factory CDI circuitry incorporates any type of variable timing feature that is dependent on RPM? That is about the only thing I can think of.
I've read other threads that discuss this "kickback" symptom and the usual culprits are weak battery or a too lean condition causing preignition. I've installed (and charged) a new battery and triple-checked both carburetors...the original one that I completely cleaned, and the Amazon replacement. Same response with both carbs, which leads me back to questioning the CDI.
Any body else run into this?
Thank in advance for your help.
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By Krazo
as title states, what are these wires? I took off the rear plastic, and right behind the brake light, these wires are all disconnected. Not sure what they go to. Aside from my current issue of what appears to be a bad coil (replacement ordered) the atv has run fine for me. I just bought it this past winter and spent time replacing front end components but motor has run fine until the this past weekend. By the looks of these wires they've been unplugged a while. only thing I can think of is they're for trailer lights maybe....? but i really don't know.
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By Wilkechr
Hi all, I have a 2003 sportsman 500 ho that I purchased a CDI for to replace the previous one however it was modified by someone else to use a different one I have all the correct wiring however I have to make the correct pigtail will anyone be willing to share a pic of how theirs is setup any help would be appreciated as I have been working on this bike for 2 months
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By rafal
Hello,
My name is Rafal and I'm 43 and I'm from Poland.
I will go straight - I'll be glad if someone could send me service manual for KVF300 2001.
Its very hard to get it from the network.
Thanks in advance.
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