Hi, Newbie to forum. Neighbor asked if I could fix his quad as I fix things. Described as a poor starter, back firing and running its battery flat. Upon receipt battery wouldn't even sound the horn, so it got charged. With a different battery horn, lights etc work. Starter? stalls.. like hydro locked. Take plug out, turns over. No spark. So, I discover HT coil is open circuit. The Cdi module has three connectors, one with 2p (power), another 4p (pickup [p5&6], HT out [p25) and Ignition Sw [p40]. I have 115 ohms on pickup sensor so ok. p25 is 0v but does go to the HT coil, p40 appears to go nowhere. I have a circuit (part of service manual), p40 should go to p37 when the ignition is OFF. where p37 goes, it doesn't say - So, confused.. The third connector is a 6p job, has NEU, FWD, REV, BRAKE, OVER DRIVE & Finally a wire that goes to fuel computer, I'm assuming tach output. (I should have scoped that for pulses - d'oh). Of course fuel computer is blank, only it's blue back light comes on. So, I guess my question is, does anyone know where p40 ends up. On my circuit, looking at ignition / main switch there is 5p, they are 1, 3, 4, 19, 40 & 37.... 3 [red/white] = Battery +, 4 [Brown/Blue] = Switched Battery +, 19 [Blue/Red] = tail lights, 40 [orange/black] comes from the 4p connector of Cdi unit, 37 just isn't connected to anything... However, I've noticed the same wires / p37 being used between FAN and FAN CONTROL SWITCH. What really confuses me, when ignition is on, according to this diagram p1,2 & 3 are shorted, 1 is battery negative..!!
Having discovered the HT coil was open circuit I replaced it with a indicator bulb and scoped for pulses - nothing.. I'm using a multimeter but also battery/bulb (test light) to confirm signals. I can't really continue with the other issues until I have a spark... I hope someone can shed some light on this problem - I'd really appreciate any help.
