500 XTC Deluxe no spark Help !

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BornYamaha

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Oct 8, 2006
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350
Location
Northern IL
"98" 500 XTC Deluxe no spark Help !

Here is my problem. I rode some last weekend. Probably about 10 miles. Mainly testing after changing to lower gearing. Everything ran great. I started and turned it off several times, no problems. This weekend I try to start it. and discover I have no spark.

- Disconnected kill switch
- Jumped out tors
- Unpluged ignition switch
- Also checked B/W wire which goes to all these to verify they are not short to ground. None
- Checked Ignition coil & plug wires. All in spec. Even swapped coil from old running Ovation which metered identicle th Vmax coil to double check.

- I checked output from charge coil. I am within spec. 245 ohms. Voltage out when pulling over I believe to be ok. It is difficult to be sure with my meter. If I pull it slow I get 50 to 60 VAC, but if I pull it over at a speed that I would expect to be used for this test as if you were trying to start it, my meter goes over scale and I can not read it. This works all the way to the plug at the cdi box.

- I checked input voltage at ignition coil wires with it unpluged orange & ground. I have pretty much nothing. About 0.6 Volts.

- As a small side note, when I let the starter turn it over the headlight does light fine.

I don't understand how a sled can sit in a garage 5 days and suddenly have these problems

Does this mean with very little doubt that the cdi box is bad or could there be something I am missing? I do not have one to try.

I am working with the electrical drawing that is in the back of users manual and some info I have been able to find here on TY so there may be something I am missing.

I don't really want to buy one to find out it is not the problem.

Thanks for any opinions or help.
 
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Sounds like a CDI problem for sure, did you check all the connection coming out of the CDI. I had a loose connection on one once and did the same thing.
 
is the flywheel rusty? look down thru the recoil hole on top of case, I have seen these ruin a guys day and all it was is rust keeping the pick up coil from reading the flywheel magnet.
 
rusty flywheel has gotten alot of guys before, I always look for it before I dive into something too far, we tend to overthink most things as humans....lol

other thing is if you have power coming out of it(pick up coil) do you have that same power at the entrance to the cdi box? and what about the output from the cdi box to the coils, whats the voltage there when you pull it over?

I always start from the source(stator/p-u coil) and work out to (spark plug boots)find a no spark problem.
 
I have 50 to 60 vac at plug going into CID box if I pull it over very slow. If I pull it over faster I am sure it is going alot higher but my meter goes out of range and the power is not there long enough for the meter to figure it out. There is no power going to the coil. I have jumped out the tors & unplugged the key & kill switch. I metered the wire for the key & kill switch and they are Not short to ground. I will check for rust like you said unless you tell me otherwise.

Thanks
Kent
 
if you checked al the rest, the cdi has to be the part thats not completing the circuit then if the power is going in and nothing coming out of it on the wire to the coils.
 
Bringing this one back from last spring. I finally got time to work on it again before it gets close to snow time. The Cdi box did not fix it. Upon more diligent checking I discovered that the pickup coil was metering nearly open, 500k ohms to 1 meg ohm. I got it pulled out last weekend. I am rather curious about a couple things. My flywheel was definitely rusty, but why would that affect the operation. I don't doubt you. I just don't see how it would affect a sensor of this type. My second question is: Would there be anything else I should look for that may have taken this pickup coil out? There were no visible marks or rub throughs on the wiring. I would hate to put a new (or used) one in only to have the problem repeat. This sled is 16 years old with 8500 mile on it. Comments and wisdom are welcome.
 
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