2004 300 EC. Stator, coil and CDI measurements

H

Hgoody77

New member
I have a 2004 300 EC. It is getting a weak spark. I have been searching online for info and have not found a source yet. Does anyone know the Stator, coil and CDI measurements with an ohm meter?
I have checked all connections, and cleaned them with no results.
So now I'm stuck thinking the stator, coil or CDI is faulty.
Any help is greatly appreciated.

Fresh fuel. New plug. Cleaned carb. Tried small amount of starting fluid.
No start.

Thanks. Howard.
 
I just emailed you a PDF of the engine shop manual. It contains all the test values. This is a very common Kokusan ignition.
 
Hey. I got the email thanks.
I looked through the PDF file. I only found readings for the stator. But the list of wires to check had more wires then what this stator has. I know my exciter set of wires rang out high. This one was like 100ohms.

Is there a place with the measurements for the coil as well?
Thanks, Howard
 
You might have a 2K-2 ignition. (small flywheel, wires exit front of cover). Only difference in specs would be for lighting coil, ignition windings and pulser should be the same. I don't remember if coil values were in there or not.

I just remembered something to suggest though. A common problem with these coils after a couple years is for the HV wire to come loose, the glue that bonds the small rubber boot to the coil body and seals things up breaks down, and lets water into the connection. Check this, and if its loose remove the HV wire/boot, cut the wire back a few mm, clean the coil up good, and thread the wire back on the screw terminal in the coil body. I use a little Honda grip glue on the edge of the wire insulation and boot to seal things back up nice. Check the plug cap side as well, and go through all your other connections. My bike is a one kick starter now after having these problems.

Another thing is the CDI harness flexes where the subframe meets the frame when the subframe is lifted up. In some cases the wires can break inside the insulation and cause intermittant operation, while still looking OK from the outside. Good Luck!
 
Ok. Took the plug wire off the coil and plug boot end. Cut about 1/4" off and made sure no corrosion on the screw part. Put it back together. Made sure that the coil frame was grounded good to the bikes frame. Cleaned every connection. Took the kill switch out of the circuit.

My cdi box has 7 wires.
White/blue
Black/yellow
Black/white
Red
Green
Black/red
Red/white


My stator has 5 wires.
Red
Green
Black/red
Red/white
Yellow

Going up the frame I have
White/blue
Black/yellow
Yellow/green


That manual says:
Impulse coil, red - green 100ohms. Mine is 100.6 ohms
Exciter, blk/red - red/white 12.7ohms. Mine is 26.2 ohms.
Charge coil, yellow - earth .67 ohms. Mine is .9 ohms
White - yellow .16 ohms. But I don't have a white wire on stator.

My stator the wires come out of between cover and engine at the 10 o'clock position.

Isn't the exciter coil the part that starts the spark/voltage to feed the spark plug coil?
 
I pulled the stator out since according to the numbers it may have an issue as well.
Some spots don't look good. But still un certain. Was hoping to find some definite answer. Ha ha. Like its that easy.
 
That's going to be the hard part. Maybe ship this one to a member to test. I dunno. Sure wish there was a value for the coil.
 
Hgoody77 said:
That's going to be the hard part. Maybe ship this one to a member to test. I dunno. Sure wish there was a value for the coil.
Click to expand...

KTM use the same/similar electric system, so you can try a ktm cdi. Probably easier to find than a gasser one.
 
My 06 cdi failed. Managed to get one to fit from a rm125. Did mean rewiring though only cost a tenner.

Try taking all coils off, place them in the oven about 50 centigrade and measure again, this may still not be definite but has found a dead coil for me before. If a coil wasn't lacquered properly it may be arcing between coils only when a high voltage is going through, replace in order.

spark plug
ht coil, ht lead and cap
stator coil
cdi

of course only after ensuring all connectors are clean and wires in good condition
 
2004 300 EC Stator, Coil

I have the same weak spark problem on my 2001 EC250. Unscrewed the plug, grounded it to head and kicked it, can not see the spark jumping the gap in the plug. But I can feel the spark on my hand, not a sharp zap but a mild one. I was thinking ignition coil, so I borrowed the one off my EXC200 and connected it up to the EC250, kicked it and can clearly see a blue/white spark jumping the plug gap. Used the same plug both ways.

From this I am thinking my stator is OK but my coil is bad. I measured it out as follows: Primary coil resistance 0.5 ohms, secondary coil 13,000 ohms. I don't hav the specs to compare this to. Can anyone advise?

I see from the parts finder on Gofasters, the coil changed part numbers in 2004, from ME25634006 to ME250434006. Anyone know what is different?

On ebay there is a 2005 coil but I am worried it will not fit.
Thanks
Greg
 
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