1988 Bayou 220 No Spark
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1988 Bayou 220 No Spark
I am trying to help a young friend of mine get his first ATV running that he bought with his own money as a project. We had spark to begin with but the starter would not spin the engine, just the flywheel. We opened up the crank case cover to find the woodruff key laying in the bottom with the flywheel free spinning on the crank shaft. (The crank bolt was also missing.) That was all easily fixed, and the starter spins the engine now but, unfortunately, when we put the crank case cover back on we managed to pinch both yellow wires coming from the stator and shorted them out. We pulled it back apart, repaired the wires, and reassembled it all but something obviously got fried because we no longer have spark.
We do have the service manual which goes into great detail on how to test all the components off the machine and have done so using three different meters. Unfortunately, the pickup coil, stator, CDI, and rectifier all test bad per the values set forth in the service manual. I'm not sure that I'm surprised by that since none of that stuff is fuse-protected, but I am a little surprised that the one short appears to have basically destroyed the entire ignition and charging system. You would think one component would get fried and then no more after it, but I guess crazier things do happen.
I mainly have two questions at this point:
We do have the service manual which goes into great detail on how to test all the components off the machine and have done so using three different meters. Unfortunately, the pickup coil, stator, CDI, and rectifier all test bad per the values set forth in the service manual. I'm not sure that I'm surprised by that since none of that stuff is fuse-protected, but I am a little surprised that the one short appears to have basically destroyed the entire ignition and charging system. You would think one component would get fried and then no more after it, but I guess crazier things do happen.
I mainly have two questions at this point:
- I have worked on tons of stuff in the past, using tons of service manuals. I have actually found many instances where the manuals have typos or incorrect values specified. While testing our rectifier and CDI, I found that several values we got, while not correct for the cell in the chart that we were actually testing for, were correct for one cell left or right and vice-versa. In fact, almost all values we measured were represented in one cell or another in the value tables, just not the actual cell we were testing for. Has anyone here ever actually tested a rectifier or CDI per the service manual and found that the cells were correct?
- I believe the starting and charging system on this machine are separate. I know that I can't get spark using the rip cord if there is not 12v present in the system already. Will it run with the rectifier and stator unplugged though? I'm mainly asking for trouble-shooting purposes so that I know, if I eliminate those from the system temporarily, if I should or shouldn't expect to be able to get spark.
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