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Stator help needed

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This is not DRZ specific, but this forum has the most knowledge.

My buddy installed a Moose lighting coil stator on his 93 cr250 to add a headlight and now the bike don't run. The plug will spark but only if you give the starter a real good boot, but no spark at low RPM. When it does spark it has a nice strong blue spark, but it has to be spinning too fast to make it run with a kick. Why would it spark at a high RPM but not at a lower RPM that would be typical of a kick start? Oh yeah, the bike ran fine before the install.

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Sounds like an overloaded stator. At higher rpm stators can make more voltage. I believe there is no battery on this bike making this problem occur. Is there a switch on the headlight enableing it to be turned off during starting. If not try this as it may help.

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He's tryed it with the headlight switch on and off with the same results. It does seem like an overload condition though. We'll try unhooking the 12v lighting wire completely, maybe the switch is shorted or some crazy thing like that. It seems like if it was a defective stator there would be no spark at all, but who knows.

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The ignition and lighting are completely separate. The lighting coil is not affecting the ignition. Was the lightng coil added to the original stator plate or is it a complete different plate? Sounds like air gap between the ignition source coil and armature magnet is too wide.

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You may have a issue with the coils of the new stator being too far from the flywheel, causing a lessening of the available magnetic field. When it does run, were the lights nice and bright. BTW, the lighting and ignition coils are seperate and should not be an issue. It is also possible you simply got a bad stator. The service manual should specify what the resistance should be in the ignition coils and the voltage available when running, might want to test this.

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It was a complete brand new stator plate with ignition and lighting coils. We have never got it running so don't know if the lights are bright or not. Noble, are you refering to the gap between the outside of the flywheel and the pickup coil or the gap between the inside of the flywheel and the ignition coils? As far as the gap between the pickup coil and flywheel, it does look like it's a little wide to me but really is no way to adjust other than perhaps bending the little mounting bracket.

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