[cottage grove]

I have two of every electrical component to my 86' trx250r. My problem started when I got moisture in the stator cover. Sat for a few months. Took off the cover. Lots of corrosion. Replaced stator with a ricky stator. Had a delayed spark. Switched out wiring harness, then new cdi, then new flywheel and another ricky stator stator. Now no spark at all. Tried spare ignition coil. Took all elec. tape off of harness to inspect for breaks or anything, all looks good. Cleaned all connections. I ohmed out every component and connections, and they are all within the appropiate ranges. Checked the ignition switch, stator, ignition coil, I have tried three cdi units. Is there anything else that anybody may know? You can't get a factory wiring harness new anymore, so my thaught was to buy another used one off of ebay or something. I am kind of at the end of the road on trying anything else. HELP

 

[Helmut]

Welcome to the forums. Did you check the pulse generator?

 

[cottage grove]

Thanks. I checked the wires from the pulse generator with my ohm meter. I was at about 184 ohms.

 

[Helmut]

Thanks. I checked the wires from the pulse generator with my ohm meter. I was at about 184 ohms.

It should read 50-200 ohms, so it's within specs, then. Sounds like you've already tried everything I can think of. I don't know what else it could be. Maybe someone else will know.

 

[TRX2fiveO]

Your Kill switch isn't grounding out is it? Re check your grounds and do what I did run a ground wire from the engine to the grounding point of the harness.

Alright Helmut get me a pic of the wiring digram so I can see it.....LOL

 

[Helmut]

Your Kill switch isn't grounding out is it? Re check your grounds and do what I did run a ground wire from the engine to the grounding point of the harness.

Alright Helmut get me a pic of the wiring digram so I can see it.....LOL

Here is the wiring diagram, but I had to get it in two sections, because my manual is secured. I had to get two snap shots because the whole thing wouldn't fit on the screen, so the diagrams are overlapped.

 

[TRX2fiveO]

I think you may have an issue in the stop switch on the bars...sometimes an aftermarket kill switch will be the culprit too.

 

[shadetree]

like trx said..check your kill switch..check all your ground wires...you said you replaced the c.d.i..did you replace it with the same year and make ???..because if you didn't..it won't work at all. it has to be for the same year and make..< been there too many times >,..lol..if the stator is the right one..and the pick up coil < pulse generator > is the right one..and you have all the wires right..and the right c.d.i..and a good coil..you should get spark...what about your ignition switch ?.have you checked to make sure your getting power through it ?..if that switch is bad..it won't fire at all.

 

[trommy]

I have used CDI's from different makes before with no problem,from similar sized engines but you have to know which wire is the trigger circuit.
Disconnect your kill circuit and ignition switch.Wire it directly to the coil but run a seperate wire under the spark plug boot as a temporary kill circuit.If it works then its in the wiring.CDI's rarely go bad.Also if you loosen the pickup coil you can probably move it closer to the rotor a tiny bit.I've had that happen before.G'luck

 

[cottage grove]

Your Kill switch isn't grounding out is it? Re check your grounds and do what I did run a ground wire from the engine to the grounding point of the harness.

Alright Helmut get me a pic of the wiring digram so I can see it.....LOL

I did check the ohms coming from the swith and it was in the correct range. I don't have a kill swith, just a switch. My frame has been powder coated, but i didn't have any issues before I had the corrosion inside the stator case.

 

[cottage grove]

like trx said..check your kill switch..check all your ground wires...you said you replaced the c.d.i..did you replace it with the same year and make ???..because if you didn't..it won't work at all. it has to be for the same year and make..< been there too many times >,..lol..if the stator is the right one..and the pick up coil < pulse generator > is the right one..and you have all the wires right..and the right c.d.i..and a good coil..you should get spark...what about your ignition switch ?.have you checked to make sure your getting power through it ?..if that switch is bad..it won't fire at all.

Thanks for the input. I did check the switch and it was in the correct range according to my manual. I also have an extra switch that I checked out by switching out the other switch and both were fine.

 

[shadetree]

I have used CDI's from different makes before with no problem,from similar sized engines but you have to know which wire is the trigger circuit.
Disconnect your kill circuit and ignition switch.Wire it directly to the coil but run a seperate wire under the spark plug boot as a temporary kill circuit.If it works then its in the wiring.CDI's rarely go bad.Also if you loosen the pickup coil you can probably move it closer to the rotor a tiny bit.I've had that happen before.G'luck

your right..c.d.i's rarely go out..butttttttttt..if your not using either a good known one..or the same year and make..they won't run..from his very first post..he stated that it fired once..then quit..i know for a fact..this is caused by a bad c.d.i..or not the right one.

 

[Ender SF]

This might sound stupid, but is the spark plug good? I know a few times when my spark plug was bad and it was the last thing I checked (obviously). I felt really stupid, but it worked. Especially if everything else looks fine.

 

[ptac]

Hey--- check---or better yet...RELOCATE the ground on your coil (where it bolts to the frame... I went through this with a trx90 --replacing parts like mad....till I did the above. Good luck

p.s. is that cottage grove Minnesota?

 

[Helmut]

Yeah, I've had problems with grounds before. That's one of the first things that should be checked. Seems like the simple problems are always the problems that get you.