Need JR's help By rangerdaver91 (Read 686 times)

[rangerdaver91]

Holy crap, can you believe this thing quit on me again. It was running great and then just died and will not start. I got it back to the house and checked it out. The first thing I noticed was the green light on the CDI was blinking very weakly when cranking it over, I had to turn the lights out to see it at all. So I decided the new CDI had gone out and ordered another one just like it. The wire colors were a little different. The orange wire is now red and the red/white is now white/red. I pulled the plug to check for spark, it has spark but shocks the shit outta you, even holding the plastic plug boot it shocks you pretty bad and it is shocking you at the handle bars as well if I am touching the bars or brake lever, Its like it scattering spark. I pulled the engine cover off and found that my cooling fan was in pieces. I was checking ohms to see if there is a short and found that I am getting a reading (maybe 7 ohms) when I touch the red/black wire from the stator and ground it to the frame. I then did the same check on the original stator on the bench and had no reading when touching the red/black wire and grounding it to the stator plate. So I pulled the new stator and checked off the scooter and did have an ohm reading when I grounded it to the stator plate (again around 7 ohms). I can not see any obvious damage to the stator or any wires. Could the exciter coil have shorted out internally since this is where the red/black wire connects ? So I am thinking I may have a direct short some where. I then did a few checks to see if I could find it by checking the ohms on some hot wires to ground, I had the battery unhooked when I did this. I found that the hot wire to the starter was pegging the meter, so I unhooked it from the starter and it stopped so I checked it at the spade connector where the hot wire hooks up coming out of the starter and when I touched my ground lead to frame it pegged the meter. Is this normal or is there a short in my starter ? It works like is is supposed to. The scoot has compression , it is getting fuel and it has spark but will not start. As you can guess I am lost in the fog again and need your expertise, I hate electrical problems and am sick of working on this thing, please help.

[JR]

Sorry Dave I didn't see this so let's review.

If the starter was shorted out as soon as you hit the start button not only would it not turn over but you would smell and see the main cable from the battery through the starter relay getting hot and melting the insualtion off. If your starter is turning the engine over without any of this and with your ohm readings you gave than all is well with it. Remember all stater windings are one continiuos wire with the end of the wire terminated at ground. If your meter had not moved at all it would indicate a bad winding and the starter would not make a sound.

On the red/black wire on your new stator it seems the 7 ohms is a little high but on my 150 GY-6 the reading is 4 ohms and stators vary so here is another instance where I see no problem, if you have spark then it's working fine. It produces AC to the CDI so it should be in the range of 50 to 80Vac so do a voltage test with the starter turning over the engine. Besides by your description of a violent shock I'm not getting that picture with just 80ac.

Don't get me wrong 50 to 80Vac would not be pleasant but my thought is if you have good spark it's not grounding out to the frame but you could test to see. Unhook the feed wire form the CDI to the coil and then see if you get shocked on the handlebars or other places. If so then you found your answer.

MY thought is you've got voltage from the coil making it's way to ground and need to check it out thoroughly.

Again hook the stator and everything back up and make sure all of your ground wires are hooked up and making proper ground and test for the shocking with the coil power feed wire from the CDI unhooked and let me know.

JR

[rangerdaver91]

I put every thing back together and did the tests. I am getting 65Vac from the red/black wire coming from the stator while cranking the motor over. With all the wires hooked up and the plug in the head with the wire on it, if I get my finger close to the plastic spark plug boot it shocks me at the plug boot and at the handle bars, I don't even have to touch it just get close to it and it bites me. With the red wire from the CDI unhooked from the coil hot wire the shocking stops but of course the plug doesn't fire either. All grounds are fine, I say all, there are only 3 grounds 1 from the battery to the engine block, 1 from battery goes into the wire harness and 1 from the engine block to the frame. I added the one from engine to frame when we where doing the harness.

[JR]

Voltage is fine on the red wire. Only two possibilities that I can think of that would cause this and on one I'm not sure.

The coil wire/cap has a hairline crack in it and jumping fire or the coil is going/gone bad and is backfeeding to ground. The later I'm not sure on? Do you still have one of the old coils? If so try a swap. Also you could fix the sparkplug to a good ground with the plug wire attached and then turn it over at night time or in the dark. This would make it a lot easier to see if it is jumping fire anywhere?

JR