2006 90tlr No Spark

[b.gandy3]

Hi guys, I'm new to this forum and I'm having an issue with getting spark. I was idling the other day, and the motor just knocked off out of nowhere. Cranked it and fired right back up and I kept idling maybe another 30 minutes and then it knocked off again. This time it wouldn't fire back up and I had to be towed in. Checked the fuel system and everything was fine. Checked for spark and I don't seem to be getting any on all three cylinders. Unplugged the kill switch and plugged it back in a couple times just to make sure that wasn't the problem. Was going to start checking voltage on the CDI, pulser coil, stator, etc so I bought a Seloc service manual only to find that it's pretty much useless because it doesn't contain any of the specs for the output voltages. If anybody knows what those specs are for my motor or has a service manual showing the specs that they could take a pic of and post that would be a big help. Also, if there's anything else you guys think I should be looking at or for please let me know. Thanks in advance to anyone willing to help.

[99yam40]

web search for CDI troubleshooting guide and find a DVA adapter to make peak voltage readings

[b.gandy3]

web search for CDI troubleshooting guide and find a DVA adapter to make peak voltage readings

Thanks 99yam40. Found the guide for my motor (never would have guessed it was that easy) and ordered a dva the other day that should be in tomorrow. Will post my findings after testing.

[99yam40]

Some times keeping it simple works

[b.gandy3]

Ok, just tested with dva and here is what I got:

Trigger: 9 volts. Specs say minimum of 5 so I guess this is ok?

Stator brown to red: 0 volts. Specs say min of 100 so I'm guessing this may be the problem.

Stator blue to red: 127 volts. Specs are min 60 so I don't know if this is good or considered too high.

Crank position: 4.4 volts. Specs say 5.5 min so this could be an issue too?

Specs also said to read black/orange, black/white, and black/yellow but I couldn't find wires of this color anywhere on the motor. Also, did try disconnecting the white wire and cranking before all testing and that did nothing. Anybody have any next step suggestions based on this info?

[boscoe99]

Brown to red is the low speed charge coil. If you got zero volts you got a problem with that coil.

Did you measure the resistance of the low speed charge coil? If so, what was the value?

[b.gandy3]

Resistance on high speed coil was 243, resistance in low speed coil was 1, which I'm pretty sure means dead. Let me know what you think.

[boscoe99]

I think that zero volts means that the CDI capacitor will not be charged in which case there can be no discharge of current to the coil in which case the spark plug is not going to spark.

[b.gandy3]

So that means get a new stator, correct?

[boscoe99]

I am not in a position to say what should be bought or not.

[b.gandy3]

Gotcha. I appreciate the help. Anybody got a suggestion on where to buy the needed tools to pull the flywheel?

[99yam40]

were the voltage tests done loaded or unloaded?
connected or unconnected

I guess it does not matter if the resistance was 1 ohm you had to be doing that with it disconnected from other things

a lot of pullers will work, but watch how far you thread the bolts into the flywheel as if too deep you will damage things under there.

see if you can rent or get one from auto zone or other auto parts place that will work

[b.gandy3]

When I did the voltage test I had the dva positive lead connected to either the brown or blue wire, and the negative lead connected to the red. Cranked the motor and recorded the peak voltage, which when connected to the brown wire just read "0". For the resistance test, I disconnected the dva and used the normal leads on the meter. I turned off the battery and did the same test. The high speed coil read 243 as it should (I believe it was supposed to be 240), but the low speed coil read 1, which as I understand it is a dead circuit. You'll have to forgive me for my lack of understanding all the terminology, I'm new to electrical diagnosis. Any problem I've had in the past has been fuel related so I've never had to dig in to this end of things. I really appreciate everyone's help and patience though.

[panasonic]

For someone new to doing electrical work, I think you are doing very well at it, very well indeed.

And as yami said watch screwing the puller bolts into the flywheel, just need full engagement of the threads that are in the flywheel holes, no more.

[b.gandy3]

Put the new stator in today and that did the trick. Have fire now and it idled fine for about 5 minutes. Still need to do a test run but all seems good so far. Thanks to everyone here who helped me out!