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99 XR 100 no spark

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I'm fixing a 99 XR 100 for a friend. I rebuilt the motor and it was starting on one kick. I was finishing it up and getting ready to turn it back over to him when all of a sudden... no spark. So I started to check things... 1st was to trim back the spark plug wire... nothing. I started checking voltage, and I think the coil is bad. When I check across the two posts, I;m getting 0.7 ohms. I think this is too low, but I don't have a a manual and cannot check it. The resistance to the spark plug wire is 3.02 which to me seems low.

Do I have a bad coil?

Edited by eprovenzano

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This doesn't deal with the coil, but just to eliminate the easy stuff, did you disconnect the kill switch closet to the coil/CID? That's what I had on a no spark, and I had Honda tell me my plug wire was bad and so on with out them seeing the bike in person.

As soon as I disconnected the kill switch, it fired right up! Just a thought... = )

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This doesn't deal with the coil, but just to eliminate the easy stuff, did you disconnect the kill switch closet to the coil/CID? That's what I had on a no spark, and I had Honda tell me my plug wire was bad and so on with out them seeing the bike in person.

As soon as I disconnected the kill switch, it fired right up! Just a thought... = )

Yes I disconnected the kill switch.. still no spark

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Based on what I've read and watched on you tube the readings should be from 3.0 to 5.0 and 12.0 to 15.0. Based on that I'd say have a bad coil

Edited by eprovenzano

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I ordered a new coil.  I'm pretty confident that the coil is the issue, but if not that's OK...   its not so expensive that I feel as though I'm throwing money away.

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While I wait for the new coil it arrive, I went through the rest of the electrical components.. I can trace power from the stator, through the Cdi to the coil leads. Was I getting the proper readings.. I have no idea. I've not been able to find that specific data, but I was getting something... The coil is inexpensive so its the 1st thing to replace.

I will keep updating with my findings

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New coil arrived and still no spark... :thumbsdn:  :naughty:  :banghead:  I'm going to pull the stator and look / test for a broken wire(s).  I'll post up any findings

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I'm thinking its the CDI, but I'm still struggling to find exact specs as to I should be getting when I test the stator.  

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I just put in an order for a clymer manual last night. It may take a couple of days, but if you can wait... I will look up any info you need if its in there! = )

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I just put in an order for a clymer manual last night. It may take a couple of days, but if you can wait... I will look up any info you need if its in there! = )

Thank You, I'd appreciate it.  In the interim, I've put a request out to a few buddies who's kids have an CRF / XR 80.  I'm hoping to swap a few things to help narrow it down to which part has failed.  

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I kept testing the different electrical components. I was getting a good signal from the stator to the CDI. The signal from the pickup coil was suspect. Do I decided to pull the stator and inspect the wires... This is what I found...

E5EAD9D1-8D9F-4219-846C-F29552FF779A_zps

The wire on the pickup coil is broken. My question... Can this be soldered, or do I need a replacement stator?

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My thought is, why not try! It is no good as it is and if it doesn't work, you will have to replace it anyway...! Right? But that is defiantly a reason for no spark. = )

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Motohead_328 I appreciate you finding and posting that info.

 

After more testing I found a 2nd break in the pickup coil.  I called the owner and told him "IF" I'm able to fix it, how long would it last...  so I advised a new stator... one with a winding for a headlight. The bike is to be used on his farm to putt around, and a light may be come in handy.  So we shall see...

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No problem... and as a utility vehicle, the third wire is a smart idea for a light, never know when you'll get caught out past dark...!

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I had to try one more time. Armed with the correct testing #'s I stated again... I knew the pickup was the issue, so I stated tracing the wire... Low and behold I found the wire broken in two places... I cut it out andI soldered in my own, it tested out good (thanks Motörhead) reinstalled and had spark. With a little persuasion she fired up and runs like a champ

Chasing down an electrical failure is a pain in the arse. But now It's fixed and the owner will pick it up later.

Thanks for everyone's help...

Oh BTW. I was able to make the plastic look 10 years younger... I wet sanded with 180 grit, then 520, and then with an S.O.S pad (it's a steel wool pad with soap). The plastics really look good I still need to hit them with a heat gun but I'm happy with the results

Edited by eprovenzano

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