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Discussion Starter · #1 ·
Okay, first things first, I'm a registered nurse not a mechanic. I'm an intelligent man but when it comes to mechanical things please talk to me like I'm an idiot. I have a 2002 TRX250EX that has been well taken care of since I bought it new. It died a few weeks back and wont restart. The starter clicks and the engine turns but never fires up. I am getting no spark to my plug. In my inexperience, I went ahead and relaced the battery (was the original), replaced the fuse and plug, and put on a new starter and ignition coil. Took out the carburetor, disassembled and reassembled it (everything looked fine to me but this was also the first carb I have ever seen. The little floats were free moving as a friend said to check that?) So Im still stuck. Im getting no spark. I've read several posts and now I'm thinking the CDI?? Any help would be greatly appreciated.
 

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Welcome to the forums. If you're not getting spark to the spark plug, it could be the stator, pulse generator, or CDI, since you've already replaced the ignition coil. It could also be a wiring problem, but not likely.
 

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more than likely it's your c.d.i..could be a bad kill switch..bad key switch..or a loose ground..but..more than likely your c.d.i..check everything before you replace the c.d.i..and if you do replace your c.d.i..please make sure you have the same year and make for your bike..or it won't fire and run !..oh..by the way..even though you took the carb off..and cleaned it..the carb won't keep your spark plug from firing.but..still..it probally needed it anyway...lol.
 

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Well First thing i would do is check my kill switch, take it off the bars and make sure that the button still moves the internal mech's correctly. After that i would trace down the kill switch wires to all the way to the cdi making sure that they are not worn and may be grounding on the frame. Let me know what comes from this. OH and welcome to the forums
 

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Discussion Starter · #5 ·
Eww i was afraid I was going to have to take that kill switch apart. Its like all one unit with the lights and ignition button. Looks like a lot of little pieces. LOL. The stator and pulse generator? What are those? Is it also true that if I replace the cdi I need to replace the rectifier as well? Thanks for all the info. I'll keep you guys posted on what I find.
 

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Don't be scared to take the switch apart its not really that much to it just watch what you are doing and take your time.
 

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Discussion Starter · #7 ·
Okay yeah the switch wasnt bad to take apart at all. Couldnt get the kill switch button off the front though. But from behind everything looks fine. Has probably only be ridden like 200 hours or less and stored inside since it was new so everything looks like new. Not even a spider web inside the casing. LOL All the wires and connections I see look like new too. Nothing coroded or anything and everything is connected. Guess I'll be ordering a cdi? Do I need to replace the rectifier too? I think I read that somewhere...
 

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Eww i was afraid I was going to have to take that kill switch apart. Its like all one unit with the lights and ignition button. Looks like a lot of little pieces. LOL. The stator and pulse generator? What are those? Is it also true that if I replace the cdi I need to replace the rectifier as well? Thanks for all the info. I'll keep you guys posted on what I find.
The stator is the part inside your engine on the flywheel side that generates the power for your ignition and it also generates the power to charge the battery. The pulse generator is also located near the flywheel and is the part that triggers the CDI when to fire.

As far as having to replace the rectifier if you replace the CDI, no, that's not true.
 

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Before changing the CDI i would take a light tester and See if im getting any power to my coil
 

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Discussion Starter · #10 ·
Thanks everyone

Replace the cdi box and it fired on the first click and runs like new. Sweet!!
 

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cool glad its running again.
 

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Great, glad you got it running.
 
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