220 bayou no spark !

[sky94]

Corey,thanks a lot,i seriously think maybe your on to something,this strip of metal definitely is not blackish in color,very much looks like chrome or polished stainless,im off tomorrow will do some more investigating,probably get back on this thread tomorrow nite with some info.....Thanks a ton,Randy

[86klf300guy]

good luck and no problem -corey-

[stu#71]

Originally Posted by sky94

Just checked ac voltage from pulser,voltage is steady with little if any change while turning over....if i plug in my spare pulser and hold near pull start gear and turn over motor i get hot blue pulsing spark,i just cant get spark from the flywheel when hooked up normally...Thanks,Randy

re the first part of your sentence above..that is why there's no spark, you have no pulse going to the CDI, coil etc.

If you've swopped to a different pick up coil ("pulser") and hold it "near" this suggests that the new pulser is picking up a signal from the magnet. If not, where else could it get it from?

If you attach the new pick up coil to the casing (ie put it all back together again), and you no longer get a spark, there's got to be something wrong here - are you sure the new pick up isn't earthing out when you screw it in or something silly like that? There's also a little plate on mine which fixes behind the pick up coil to hold the wires away - are you sure you've got this installed correctly? The pick up needs to "see" the wheel.

Hope this helps..?

[ronnyboy]

hi there,well i hade the same problem on my bayou 300 1989 i found it. it is the relay that is beside the starter solenoid in a round rubber envelope,don't know if you have one but its not cdi, strator part number on relay is 056700-5260 hope the will get you going again.

[sky94]

Tried different relays,no change,question i have ...the raised area on the exterior of the flywheel supposed to be magnetized all the time?Mine has no magnetism ever.....the only magnets are on the inside of the flywheel....there doesnt appear to be anything to break the pulse to earth of the flywheel,therefore no pulse.....this raised area doesnt even look like a magnet,more like a piece of stainless...Any ideas?,Randy

[sky94]

One other thing to add to this is that im certain the battery on this bike is bad.......during all of my tests ive had a charger hooked up along with the battery to provide voltage....really dont want to spend another 50 bucks for a battery until i get to the problem.Is this an issue?....Thks,Randy

[ronnyboy]

its a relay that is beside the starter solenoid in a round rubber envelope part# 056700-5260

[ronnyboy]

its the relay that is beside the starter solenoid in a round rubber envelope

[sky94]

Tried relay off my running 220,no difference,also tried one off my buddies running 220,no spark...Thks,Randy

[stu#71]

I'm not sure that is a magnet - isn't it an electromagnetic field created by the spinning of the wheel?
I have a manual on it's way - I need to look it up for you...
Mate - you need to use a good battery for all of this. If the battery hasn't enough juice, you wont get a spark

[sky94]

Not enough voltage even with the charger hooked up?Randy

[86klf300guy]

with out a battery you will still get a pusle of spark generated my the magnetic field beteewn the pick and the fly wheel.the stater will give you juice to power it up on pull start.but will not run correctly with out that battery.

you guys are lucky to have a pull start for my bayou doesnt have a pull cord ,so if i die in the trails im struck and gettin pulled home lol-corey-

[86klf300guy]

stu you may have hit the nail on the hed ,iv just tore into one today and if that sapcer is not behind the pulseing coil puttin it over the magnet on the fly wheel you will not have spark pulse.the pulser would be to far inwards and not over the magnet.

this is why maybe the pulser that is being held out side the case is pulseing it is pickin up the magnetic field......

[sky94]

My pulser also has the spacer and it lines up correctly with the flywheel,still no spark.....is the charger hooked up to the bad battery enough voltage?Maybe not voltage problem,maybe amps out from charger not enough?

[stu#71]

HI Sky - just trying to rule out the obvious - that spacer - it has a bend in it right? Is that bend installed so that it holds the 2 wires leading to the pick up coil away from everything ie it pushes the wires to the back of the casing, keeping them clear of the view the pick up coil should have of the wheel?
PS mine is a KLF300 so may be different!
The only other thing I can think of at the moment is you could try moving the good pick up coil towards the engine casing and telling us when it stops working (ie you no longer get a pulse)

[sky94]

Wires route to the back by the case clear of the pulser....when i hold the coil near the pull start gear,it can be almost 1/8 inch away and still get spark...while its turning over,Picture the starter gear looks kinda like a crown,i think the pulsing comes from the gaps in the "crown" Thx,Randy

[sky94]

Also,anything further than about an 1/8 inch away from the gear,no spark Randy

[stu#71]

Originally Posted by sky94

Wires route to the back by the case clear of the pulser....when i hold the coil near the pull start gear,it can be almost 1/8 inch away and still get spark...while its turning over,Picture the starter gear looks kinda like a crown,i think the pulsing comes from the gaps in the "crown" Thx,Randy

Hi Randy. The crown thing you mention is to do with the pull starter I believe - it's the "pulley" - nothing to do with the creation of a pulse - does it have a big bolt in the centre of it?

I'm wondering whether it's earthing out somewhere when you install it? It's got to be getting a signal from somewhere!!!

What is the resistance of your pick up pls? Stick a meter across the 2 wires pls. 1988-94 220 models 83-150 ohms. '95 on: 100-150 ohms

According to my manual your pick up air gap should be 0.7mm +-.25mm (1988-94 220 models)

Exciter coil resistance (88-94 220 models) 100-190 ohms (we've not mentioned this yet, have we?)

Also the magnets, I think are internal of the rotor - check these. I'm guessing the silver strip on tthe external is a balance perhaps so it spins true - not sure tho

[sky94]

Doesnt pulse by the case and yes a14mm bolt threads into the crankshaft with a keyway to hold alignment.....tha whole flywheel is earth,attached test lite to positive on battery,whole flywheel is ground with entire motor..pulser is direct bolt to ground on installation...even tried grounding my exterior coil.made no difference..Randy

[stu#71]

Right ok, that crown thing is the pulley, same as my model. Can you post the numbers re my above post and also what year is your 220 (I have the wiring diags available here now!)