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Post by JR on Oct 2, 2015 5:29:16 GMT -6
OK I've not dealt with the single plug CDI but I'm sure we can find a pin diagram for it but I just thought of something. The GREEN wire make SURE it is hooked to a GREEN wire the same one you use for ground on other things, in other words make sure it is hooked to a GREEN wire that goes to the NEGATIVE side of the battery. The other wires we know are correct or it wouldn't even run.
I'll check to see if I can find a pin out on this CDI, if the black/white is wrong there is only one other spot for it to go? But make sure that GREEN wire goes to ground.
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Post by o0ohakko0o on Oct 2, 2015 5:47:01 GMT -6
G'day JR its correct the green wire from CDI goes to ground also connects to negative so that's fine
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Post by o0ohakko0o on Oct 2, 2015 5:54:02 GMT -6
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Post by JR on Oct 2, 2015 6:21:11 GMT -6
OK I found a diagram and here it is:  According to this your CDI wiring is correct. So now again let's check to make sure you have that green wire to it hooked up properly and another thing you can check is to be absolutely sure the BLACK/WHITE wire on the plug is making very good contact on the CDI pin. You did both the key switch and the engine run ON/OFF switch tests and they were correct, we know we are sending a ground (negative) connection when used. When the engine started you should have be able to turn it off with the key switch or the engine run switch in the OFF position. Let me know what you find out. JR |
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Post by JR on Oct 2, 2015 6:25:59 GMT -6
Yes that is the same diagram I found and the wires on the CDI are correct so follow the instructions on my last post. Got to be able to kill the engine. So the green wire is correct so now check the BLACK/WHITE for a good connection. Sometimes new electrical things have a coating mon the pins when new.
We need to be able to test both switches without the machine running off on you, take the chain off so the engine will only run. Did you figure out how to idle it down?
Here is a test, put the engine run switch on the handlebar in the OFF position after you check the black wire and see if it will start?
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Post by JR on Oct 2, 2015 8:36:45 GMT -6
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Post by o0ohakko0o on Oct 2, 2015 22:41:36 GMT -6
The black/white wire has no coating so that's fine
i started her up idling fine now still have a problem though with turning it off ? lol its very strange its starting up with the kill switch on the handle bars on the OFF position and also the key switch in the OFF position either way its starting up on or off and i can only turn it off by pulling the spark plug lead off
and i have the chain off just to be safe right now lol
what i dont understand with the tests we had done they were correct with the test light ?
Also we still dont have the solid white , green and yellow from stator connected up could this have anything to do with it not shutting off the quad ( just a thought )
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Post by JR on Oct 3, 2015 3:20:49 GMT -6
No but we need and I thought you had them hooked up so let's do that and it's simple. Those wires go to the Regulator/Rectifier = R/R.
Way back on page #1 of this thread Reply #7 Picture #4 is your R/R and the plug you have in it is these colors:
RED
YELLOW
GREEN
WHITE
They tie into the wires from the engine pigtail apples for apples and the RED from the R/R goes to the positive post on the battery to keep it charged while running. After you tie these wires in check to see if it will not start with the engine run switch on the handlebar in the OFF position. I don't think it'll make any difference at all but if it does then it's weird for sure.
If it makes no difference at all then the only answer is you have a bad CDI and yes it happens, never saw one that the kill function was bad?
But we have a way to cheat it to make it work. After you get the R/R hooked up and see if it makes a difference and if it doesn't here is what we will do.
Using the little screwdriver or paperclip I want you to remove the BLACK/WHITE wire from the CDI plug. I then want you to plug the CDI back up and if you can just slide the BLACK/WHITE wire for this test into the slot of the BLACK/YELLOW wire going to the coil.
Turn the key switch ON
Turn the engine run switch on the handlebar to the OFF position.
Turn the engine over to see if it will start.
Now make sure the BLACK/WHITE is making good contact with the BLACK/YELLOW no matter how you have to temporarily jury rig it together.
If the engine won't start then turn the engine run switch on the handlebar to the RUN position and see if the engine will start, if it does then turn the key switch off and see if it kills the engine.
If you can do this before I leave this morning I'll answer any questions by 7:10 my time. I'll be going to a softball game with my granddaughter after that until late this evening.
JR
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Post by JR on Oct 3, 2015 3:32:04 GMT -6
OH here is something else that we need to make sure we do, where the R/R bolts up to the frame I want you to make sure the frame is clean here and free of paint as in clean bare metal, scrape it off if needed then bolt the R/R back up AND
I noticed this, the big BLACK wire from the NEGATIVE side of the battery is bolted up to the engine and that's fine but wee need to ground the FRAME of the ATV also so use any piece of wire preferably GREEN and hook it up on the engine block where the big BLACK battery cable hooks up and then hook it up anywhere on the FRAME, you can even bolt it up where the R/R bolts up, this possibly could also be why our engine won't die when turning things off. Do this before the pulling of the BLACK/WHITE wire on the CDI plug along with hooking up the R/R.
JR
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Post by o0ohakko0o on Oct 3, 2015 3:38:07 GMT -6
ok ive got to hook up the r/r i dont have that connected at all i'll get on it and with the red wire can i splice that into the red going to positve side of the battery ?
also i have another 2 spare CDI's should i try those before doing this trick ?
i'll hook up the ground wire also from block to frame before trying another cdi and the trick
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Post by JR on Oct 3, 2015 3:54:52 GMT -6
YES! Splice the RED wire from the R/R to the RED fused wire that goes to the positive side of the battery, this will keep the battery charged while running.
YES! Try the other CDI's .......after you complete the wiring as instructed if the new one still won't kill the engine when it is supposed to.
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Post by JR on Oct 3, 2015 3:58:20 GMT -6
BTW how does the engine sound? Also remember after you let her warm up good then after the engine cools off to bone cold you need to re-check the tightness (torque) of the head bolts to make sure they still feel tight.
Also I would let this engine run for a hour or so and drain the oil and put in clean fresh oil, remember NO SYNTHETIC!
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Post by o0ohakko0o on Oct 3, 2015 4:19:00 GMT -6
Yes JR the engine sounds great i think minor adjustments on the carby might help a little but im unsure what its kinda meant to be like if you know what i mean if its to lean , rich etc it does seem to feel like there is alot of vibration when engine is running also a little bit of oil coming through the side gasket plate cover where the timing sprocket is
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Post by JR on Oct 3, 2015 4:29:05 GMT -6
The gasket is a easy fix, take the cover off, clean it well and then use some of the gasket sealer you bought, can even use the RED HIGH temp silicone gasket sealer if you want.
The link I gave you on the ATV sight has great instructions on how to fine tune the carb, also she'll probably be a little rough until the rings set good and she breaks in, may have to re-adjust the carb a time or two during the break in process.
I'm glad it's running!
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Post by o0ohakko0o on Oct 3, 2015 4:38:38 GMT -6
I'll have to attack the rest of the wiring and testing of the bike in the morning as its 8:30pm here in Australia
My kids are so happy its running and me also from your great expertise from it sitting in the shed for years thinking it will never run again and i found this site and 110% you guys have never let me down. Alot of other people would'nt help out like you guys have and ive learnt so much from you JR i cant thank YOU enough wish i could do something for you for all the help that you have given me
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