2001 Yamaha Big Bear 400 - Spark Issue

[motox88]

This has been a frustrating one to figure out, but long story short I've replaced just about every component on the machine and I'm still not getting spark. Or at least not how it suppose to work...

When the engine is turning over it does not spark at all, but sometimes when I let off on the start button it will spark just once. I've played with this numerous times and it will only generate a spark like this. I've seemed to somehow come to the conclusion that this correlates to the engine or crank "rocking" backwards. Depending on where it is in the stroke the crank will rotate back in the opposite direction when the starter motor dis-engages.

I thought maybe I had a polarity problem, but this is where I'm stuck. If it is indeed a polarity problem what could cause it?

If it's not a polarity problem is it just categorized as a "weak" spark issue?

Everything seems to ohm out fine, continuity checks at each plug check out, etc, etc....

Throw me some ideas. PLEASE!

[oxidized_black]

the guy i bought my 91 big bear from replaced everything electrical except for one thing and never had or got spark. did you replace the stator? is your bike an 88?

first thing i did was replace the stator and had spark ...

[motox88]

01 Big Bear 400.

Ignition coil, stator, pickup, regulator, wire harness, ECU..... all replaced.... :sadly: lol I beginning to wonder if the stator came bad. I need to validate the kill switch and the ignition key switch still.

[oxidized_black]

oh crap !! is the stator an OEM ? i know with mine (aftermarket) i had to switch out at a connector, a red and white wire ... instead of red to red at connection, i had to red to white and white to red ...

[motox88]

Not OEM. You think the aftermarket one might have it backwards at the connector?

Here is what the connector wiring is (per the manual)

R= Solid Red

W/L = White w/blue

W/G = White w/ Green

W/R = White /Red

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Edited December 28, 2013 by motox88

[oxidized_black]

well, on mine, there were 2 wires coming out of the engine, a red and white with a connector on the end. when the connection was met, the wires are red to red, white to white, i was told to switch the wires and after i did, i had spark ... maybe a longshot but worth a try ... did your instructions say anything about switching the wires?

[oxidized_black]

i was able to poke the wires in the connector and rearrange them without destroying the connection ...

[motox88]

might be onto something. If these two wires are the charging/direction wires and I'm only noticing spark when the engine "rocks backwards" then maybe they are wired incorrectly from the stator supplier.

[oxidized_black]

it might be that they are wired right, but not able to wire them the same as oem due to copyrights or pattens ... i never saw that i had to reverse the wires until a buddy looked at the little piece of paper that came with the stator, then we tried it and it worked ...

[gears]

that was common on stators from Rick's Electric - I know on my RZ the wiring switched OEM between years, maybe the aftermarket one is the same physical unit across years with that wiring reversal.....

[motox88]

As it turns out the R & blue/white were reversed (on the stator side). I had to unpin them from the connector and switch around and what do you know..SPARK!!

Thanks the help guys. Hopefully thins can help someone in the future.

[rider001]

I replaced my stator and put the cover on it, started right up. However the gear shift lever will not move. I attached two pics of both the crankcase and crankcase cover. In the pic with crankcase cover there is on item I am pointing at with a screwdriver. It looks like a deformed fork with two fingers. What orientation is that supposed to be when closing the case?? byter1 at gmail.com for direct emails.