2004 Gas Gas 300ec new loom no spark !

[Packman]

Ok so ive just had the engine rebuilt becouse of water damage she was running sweet before that. Ive had the frame powder coated as well while its in bit

The loom was looking well past its sell by date so i gave it to a mate to make up a new loom as he does a lot of bespoke stuff for cars with good success ....

While he was there he took out the indicator wiring and any other bit that was not needed .... he has replaced color with color and new plugs all round

So yes you gessed it we have no spark so there is few question i need to know !

what color goes on the coil ?

and what voltage readings should i be seeing out of the wires when i kick it over ?

 

[Fred1956]

Powder coated frame may be your problem, make sure all your grounds are cleaned GOOD (as in grind the powder coat off)

 

[Packman]

Ive just got one ground, its under the coil at one end and yes i ground it off with a grinder ...

 

[thejackrabbit]

make sure you're engine is grounded out, on either the head stay or the bottom mounting bolts

 

[Packman]

Ok will do the head stay as its easier to get at and i dont want to drain any fluids out ...

The head stay bars to the frame are aley is this still ok for grounding ?

 

[Coop]

what color goes on the coil ?

and what voltage readings should i be seeing out of the wires when i kick it over ?

Depending on the year it could be a blue wire or white/blue wire to the coil.

Depends which wire you are measuring the voltage from.

Yellow from stator = ~7V
White from stator = 9-12 V

If you measure past the voltage regular you are only going to see 5-6V.

 

[Packman]

Right made up two 7" earth straps. I removed the front engine stays to the front of the fame. Ground back to the metal and put a strap each side.

Still no spark

 

[Packman]

Depending on the year it could be a blue wire or white/blue wire to the coil.

Depends which wire you are measuring the voltage from.

Yellow from stator = ~7V
White from stator = 9-12 V

If you measure past the voltage regular you are only going to see 5-6V.

Is this while im kicking it ? sorry electrics arnt my thing

 

[GasGasDreamer]

disconnect your kill switch.
i've seen that be an issue.

how are you checking the spark?
with a new plug grounded to the engine in the dark?
with a meter?

 

[Packman]

disconnect your kill switch.
i've seen that be an issue.

how are you checking the spark?
with a new plug grounded to the engine in the dark?
with a meter?

ive disconnected the loom to the kill switch still nothing , I turn the light off and ground the plug on a headbolt and the son tell me if he sees a spark while im kicking it

 

[Coop]

Is this while im kicking it ? sorry electrics arnt my thing

Yes you have to kick it. You may see occasional spikes on the wires from the stator (like for example 14.5V from the white wire which may or may not be in use depending) but those numbers are pretty close. If you are seeing very high numbers or lower than what I posted, that is a problem.

What kind of voltages are you seeing?

 

[Packman]

There is nothing coming off any of the wires from the stator loom it was ok before with no problems all ive done is cleaned the thing up as it was in a right mess with mud and water ingress

 

[Coop]

You need to check the two coming straight from the stator; before they even get into your buddies homemade loom. If there is voltage there you buddy made a mistake somewhere or you made a mistake plugging things in and that may prove challenging to find.

 

[sweeper]

There is nothing coming off any of the wires from the stator loom it was ok before with no problems all ive done is cleaned the thing up as it was in a right mess with mud and water ingress

Has this issue been resolved?

Don't worry about your new loom for now.We can isolate the critical components and wiring.Let me know.I think we can get it sorted out.Always easier with the bike and a beer handy though.

 

[Packman]

Sorry for the slow reply guys , there is jack """t coming out of the loom as i said it was fine before it inhaled all the water and mud.

All i did was clean the stator and flywheel as they both looked terrible

What is the gap between the flywheel and the pick up suppose to be ?

A new stator is around ?75 uk as im running out of cash ......

 

[sweeper]

You'll need a multi-meter to get started.

When you say "new loom" do you mean the chassis wiring or did your friend rewire any of the ignition components;stator-pickup-cdi-coil?

It is a fairly simple process to isolate the issue.
Isolate the ignition system from the rest of the bike wiring.
The cdi-stator-pickup are connected together.
Those components get tested individually by value.
With an ohm meter.If you can't get the values their is another way.

Make sure the kill switch wire is disconnected and tape it up for now.Disconnect aux power wire..Make sure the ignition wire has a good connection to the coil.

Build a ground wire 14-16 gauge wire with 2 ring terminals long enough to go from the same ground bolt as the coil and as close to stator backing plate as you can get.If you can use one of the stator backing plate bolts and clear everything better.You'll remove it later..

Use an electrical grease on all the connections.
All you want right now while you test is a single ignition wire to the coil a good ground and the closed system connected.
Pull the plug so you get a good kick.
If you have e-start.Disconnect the entire system including the starter and the rest and throw it in the garbage can.

 

[Packman]

All the wires have been replaced coil - ecu - stator. Plugs are new as well.
The wire colours have been replaced by the same colours so were ok there.

Ive got a new stator to pick up later today so i will pop that on and see if ive got power out of that as well ....

Will report back after ive fitted the stator and kicked it over !

I freeking hate wiring !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

[Coop]

Be certain you check the wires straight out of the stator before they even go into your buddies loom. I am not bashing his work. I am saying when testing electrical devices you need to eliminate as many variables as possible. Good luck and keep us posted.

 

[Packman]

Ok so ive spent ?116 on a new stator fitted it and there is still no power coming from the stator :confused

Got the earth cable from the multimeter on the of the heads of the bolts that hold the stator on and one at a time kicking it and nothing ....

 

[Packman]

Right work this out , i get no volt reading by testing each wire one at a time and kicking it ?

Ok so i make a fly lead up because the new stator comes with bullet and spade connections and join it together.

Kick it over with the plug resting next to the head and we have spark and a strong one at that ?

Put the plug in and kick it once and ding ding ding ding ding

can someone explain ?