[regret21]

I got this Recon because it had a bad rod bearing, it knocked while running. I have replaced the crank, rod, and piston to fix that problem. Now the thing doesn't have any spark. I have a peak voltage meter, from work, and it showed that the pulse generator only made .36v AC and the service manual said it should be .7v or higher. I have replaced the pulse generator with a new one and I now only get .256v AC. I have ohm-ed out the new and old pulse generator and the old one has 368 ohms and the new one has 348ohms. Still no spark. I replaced the coil, because it was cheep and I have 0v at the blue/yellow coil connection. I get well over the 100v minimum for the stater and at the ICM. I tested the kill switch and the ignition switch at the ICM as well. The fuses and the diode was tested as well.

I think the issue is still in the pulse generator as I dont get the minimum required voltage but I dont know what else to do. I checked the wire inside the case to the connector and it ohms out at 48ohms. The ground wire in the connector to the casing is 48ohms also. (resistive wire?) I would rather not just throw parts at the problem.

Any ideas?

 

[Colasonojon9]

I just had to go through an 04 trx250te and it ended up being several things 1) bolt came out of magneto chewed up stator and magneto, replaced both including the pulse gen. Still no spark... 2) disassembled again found the black and red wire on the new stator got pinched so i soldered it and made sure the pulse gen was moved as close to the center as possible this matters!! It will giv low peak volts if too far away id atart there

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[regret21]

From what I can tell there isn't a way to check clearance for the pulse generator. The pulse generator is mounted to one 1/2 of the case and the fly wheel is on the other. I was thinking that might be the issue, but it doesn't appear to be adjustable. I was going to try bending the mounts, but they are very rigid. Thats why I was suspect on the wires having 48ohms of resistance. I'm not sure if thats normal or not.

 

[Colasonojon9]

Even the smallest adjustment can make a difference i would just loosen the screws and push it towards the center it doesnt look adjustable but it does move when you loosen a turn or two. May not be your problem but it could be. Also did you get the pulse seperately or in a stator kit they are finikey

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[Melatv]

Hi Regret21: When you touch the meter leads together on your meter does the meter read zero???

 

[regret21]

I purchased the pulse generator separate as well as the coil separate. I was thinking about trying to bend the pulse generator closer to the flywheel. I would like to check the clearance, but I dont see a way yet. I might just have to 'wing it' .

Yes the meter reads 0.000v. Its a Fluke 85 Process meter. We have them calibrated by Fluke ever year. Only thing I'm not sure is the ohm load across the meter. The service manual says it should be 10M ohm load.

 

[regret21]

So I finally got some time to pull the motor again. Bent the mounts on the old pulse generator till it made slight contact with the flywheel when turned by hand. I still get .36v AC when cranking on a fully charged battery. Any more ideas? Only thing I can think of is bad wire, as I can't check the voltage at the pulse generator directly.

 

[shadetree]

is neutral light on ?, have you tried tapping on c.d.i. while cranking over ?.

 

[regret21]

Yes, I have tried tapping on the CDI and I get a neutral light. I pulled all the connectors and cleaned the little bit of dirt in each. The ES works fine and I can shift through all the gears including getting back to neutral.

 

[regret21]

Ok, so I replaced the wire from the pulse generator to the 2pin connnector and I get the same result. Suspecting the meter can't read the max voltage correctly. Maybe the CDI is bad, IDK. Any way to test the CDI before I have to order a new one?

 

[regret21]

Borrowed a known good CDI from a running 2007 Recon 250. Still no spark what so ever. I'm out of ideas.

 

[Colasonojon9]

I purchased the pulse generator separate as well as the coil separate. I was thinking about trying to bend the pulse generator closer to the flywheel. I would like to check the clearance, but I dont see a way yet. I might just have to 'wing it' .

Yes the meter reads 0.000v. Its a Fluke 85 Process meter. We have them calibrated by Fluke ever year. Only thing I'm not sure is the ohm load across the meter. The service manual says it should be 10M ohm load.

They say to order the pulse gen and staor as a kit. I was given the example: "if you have 2 atvs and niether run and you swap pulse gen on the two atv they both start right up" this is because some cdi's need more or less resistance to send spark signal to coil pack. So if u cant figure it out order the whole kit from rmstator.com

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[retro]

I got this Recon because it had a bad rod bearing, it knocked while running. I have replaced the crank, rod, and piston to fix that problem. Now the thing doesn't have any spark.

The Woodruff key indexing the flywheel to the crankshaft might be missing or has sheared. I am assuming that the crankshaft you installed in the motor was a new OEM Honda crank?

 

[regret21]

Good idea, but no the key is there and in good shape. The crank is not from honda, its a Hot Rods brand crank / Rod assembly.

I guess it could be the stator. What else is there in the system at this point. My meter reads OL when cranking on the stator output wires.

 

[retro]

Are you checking the resistance in each stator winding or the AC voltage while cranking? I'm confused by what you said...

 

[regret21]

Im checking the 3 pin plug. Two red wires and one green. Testing each red + to the green -, AC volts, max volts on the record function on my fluke meter.

 

[retro]

I'll attach the relevant FSM component testing pages to this post for reference. The Fluke DMM you are using is a great meter but it may not be capturing the voltage peaks? You may have to use a peak voltage adapter inline with the multimeter... dunno cause I never used that model before. I have owned a few Fluke 177 meters and those would not read the peaks accurately until a PVA was hooked up.

 

[regret21]

Yeah thats what I was thinking. I need to order a PVA, I don't have one. IDK what else it can be, when the CDI has been changed out with a known good, the pulse generator and the coil has been replaced, and all the switches have been checked. Pretty much just leaves the stator left from what I can tell.

 

[retro]

You can make a PVA too:
http://www.hondaatvforums.net/forums/atv-media/120450-make-your-own-test-adapters.html#post1189570

There is only one winding in the stator that you're interested in at the moment... the exciter. Nevermind the alternator windings.