summit no spark

[jdtech65]

Well I finally got around to checking the ignition components with my fluke meter. I verified the kill switch and dess switch are both good. The ignition generator coil also tested out fine. I then went to check the trigger coil and the spec is 190- 300 ohms. But instead I have 2.621 M ohms or roughly 2,621,000 ohms. So I would assume that this means the trigger coil is faulty, correct? I also checked the primary winding resistance in the high voltage coil and that was also in spec. I did remove the air box to make testing these parts easier and noticed that one spark plug wire was getting some wear on it from rubbing on a hose clamp. It wore through the hard plastic cover and it looks like it just starting wearing into the plug wire, but since it tested good and since it was only on one wire should I replace the trigger coil since it is out of spec?

 

[skank]

I go through stators in my factory mod sleds occasionally and when it happens the headlights still glow when pulling the rope but no spark. The lighting coils on the stator dont fail very often. It is usually the ignition coils that go bad first. From the sounds of the testing and swapping that you have already done its gotta be your stator that needs replaced.

 

[jdtech65]

Just thought I would give an update. I did some testing according to the tech manual with my fluke meter. I found very excessive resistance in the pickup coil. I have about 2.4 Mega ohms of resistance, when spec is 190-300 ohms. I also verified this with another similar sled and that one had 219 ohms. I ordered the pickup coil and am installing it this weekend. So it should be running by Saturday afternoon.

 

[jdtech65]

Pickup Coil was bad.

Well I got around to replacing the pickup coil today. It wasn't to bad to do, I used a harmonic balancer puller to pop the flywheel off. The hardest part was trying to get the grommet back around the wires and back in the housing. I ended up just puting it in from the flywheel side instead of the backside. But at least now it has spark.

I don't think it is getting any fuel though. It also looks like the mag side piston is getting a lot more oil than the pto side. Is that problem in the carbs or what could it be?

Also it looks like the intake boots are starting to rip. Can you get just the boot or do you have to buy the reeds also?

 

[sledhed]

The intake boots delaminate - a factory issue, and if you don't catch it in time and repair or replace the boots, you end up with a lean condition and possible melt down. I have repaired some (after thorough cleaning) with high quality silicone sealant and had good luck.

I skimmed this thread so forgive me if I am suggesting something you already did, but I would suspect the carbs would be varnished up after sitting that long. That will plug up the jets etc., so I would pull the carbs and disassemble them and clean them up. Even if they look pretty good all it takes is one blocked passage, one piece of crap in a jet to cause a no-start or worse yet a burn-down.

Buying the stock boots is expensive as they are a unit with the cage and all. Almost cheaper to buy a set of vforce. I would take the boots / cages out and repair them if it were me (in fact I have done that to a couple successfully). You would already have the carbs out to clean them, making it easier. Just be careful not to strip the threads on the bolts holding in the reed cage / boot units... clean them up good so the silicone adheres well, including down in the gap where they are separating, bending the boot around a bit if necessary to get full access, fill all gaps and delaminated areas with silicone (the black stuff worked good, so did clear automotive), allow to dry thoroughly. Mine ended up stronger than the original.

Good luck. Love my 02 ZX!