03-06 wiring question

[slickerthanyou]

I have been fighting this, damn wiring, so i can get my heat cycles done.

Here is were im at, grounds all good (and I did grind off the powder coating to bare metal, applied dielectric grease to it also at every plug to!).
I deleted the tors (remember this is an 05 model, so you have to jumper the yellow/blk stripe wires with black ground wire on the throttle switch and the carb switch), I did this even soldered the wires togther then shrinked it, taped it up. The oil gauge and light wires I left unplugged, also I do not have the headlight/brakelight hooked up, I also don't have the, brake switches plugged in and the parking brake is deleted so I left that unplugged.

I tried jumpering the parking brake same problem, tried jumpering the brake light switches, same problem, tried just one of the switches, same problem hooked up the brake light and tried all this, same problem. Gas is good, have banshee petcock great flow, floats perfect.

It starts first kick everytime , idles sh*tty, adjusted air screw and/or idle screw has no effect, but it will idle! When you hit the gas, low boggg will not rev and will die if you stay on the gas. I am jetted rich ({33PWK} 160 main, 52 pilot) that's the closest I have now, I should be down about 155 or so and maybe one size down on pilot - but not so rich that it would have these symptoms.
Yes it it leak tested and tight, Compression before it has been started is 160psi.

Anybody have a guess as to what I may be missing before I Ditch this 05 wiring for the older year!

 

[EZRider76]

Good Fuel? Good Air Flow? Why is it bogging, have you pulled the plug to see if it is fouling? Could your stator be bad?

I think something is going on, a lot of guys are reporting a lot of bogging problems it seems like. I've followed everyone's advice on my Blaster, but I can't seem to get the needle and main right, it bogs for me at 1/2-3/4 unless I completely lean out my needle, then it just cuts at WOT. I wonder if there is a ridiculous amount of moisture in the air this year, it was a messed up winter.

 

[blasterdemon7]

I take it you did the same with the coil mounts. Did you check for good system voltage ?

 

[slickerthanyou]

I haven't done any electrical troubleshooting as I am getting spark. just seems as if something is holding it back,

The stator is brand new, I am going to troubleshoot just wanted to see if there was something stupid I was missing, I am running the nology coil and wire as a lot of guys are doing, just seems as if the tors or parking brake switch is playing games? But I have tried every possible option with those.

 

[slickerthanyou]

Good Fuel?
I think something is going on, a lot of guys are reporting a lot of bogging problems it seems like. I've followed everyone's advice on my Blaster, but I can't seem to get the needle and main right, it bogs for me at 1/2-3/4 unless I completely lean out my needle, then it just cuts at WOT. I wonder if there is a ridiculous amount of moisture in the air this year, it was a messed up winter.

^^ Scientifically speaking of course!

That made me chuckle!

 

[blasterdemon7]

Good Fuel? Good Air Flow? Why is it bogging, have you pulled the plug to see if it is fouling? Could your stator be bad?

I think something is going on, a lot of guys are reporting a lot of bogging problems it seems like. I've followed everyone's advice on my Blaster, but I can't seem to get the needle and main right, it bogs for me at 1/2-3/4 unless I completely lean out my needle, then it just cuts at WOT. I wonder if there is a ridiculous amount of moisture in the air this year, it was a messed up winter.

It could be the quality of the fuel. They add that ethanol and god knows what wlse to it.

 

[slickerthanyou]

It could be the quality of the fuel. They add that ethanol and god knows what wlse to it.

It runs good in the raptor however!

 

[blasterdemon7]

That was just a reply to ezrider. I don't think it's the fuel that your dealing with. I just wonder if it's your reeds giving you the problem.

 

[Blaaster]

The only other things I can set my mind to is faulty cdi unit, poor pickup coil or a incorrect resistance in the secondary coil.

 

[slickerthanyou]

I'm gonna use the troubleshooting guide this weekend, and see what the hell is going on. If anyone is running an 03+ harness and have the tors, parking brake, oil light and gauge deleted, please post what your set up is, IE; wires spilced, or just left uplugged. It has to be something simple I just can't put my finger on it, I'm gonna put the older harness on and ground the green stator wire, just to rule out the wiring, my problem is when I bought it, it wasn't running. so i don't know if the harness is good, however all appropriate items were plugged into the harness no butchering to it was eveident!

 

[EZRider76]

I'm gonna use the troubleshooting guide this weekend, and see what the hell is going on. If anyone is running an 03+ harness and have the tors, parking brake, oil light and gauge deleted, please post what your set up is, IE; wires spilced, or just left uplugged. It has to be something simple I just can't put my finger on it, I'm gonna put the older harness on and ground the green stator wire, just to rule out the wiring, my problem is when I bought it, it wasn't running. so i don't know if the harness is good, however all appropriate items were plugged into the harness no butchering to it was eveident!

Maybe that is the problem. Start it up and get it idling, Get a 60W lightbulb and stick it in your mouth and start touching things, if the light bulb glow maybe you have an open ground. I:I

Ok, seriously. Is there anyway to test how much current there is to the spark plug when you give it some throttle? Just have been wondering that myself, always curious if the plug is firing at the rate that is should be as the RPMs increase. Not a timing issue.

 

[slickerthanyou]

Maybe that is the problem. Start it up and get it idling, Get a 60W lightbulb and stick it in your mouth and start touching things, if the light bulb glow maybe you have an open ground. I:I

Then my penis smokes too much!

Ok, seriously. Is there anyway to test how much current there is to the spark plug when you give it some throttle? Just have been wondering that myself, always curious if the plug is firing at the rate that is should be as the RPMs increase. Not a timing issue.

Never really thought of that, maybe just put a clamp DVM, over the plug wire and tell us!

 

[EZRider76]

Then my penis smokes too much!

Never really thought of that, maybe just put a clamp DVM, over the plug wire and tell us!

Might be running too rich then.

I'm no good with electrical, since getting bitten a few too many times, I tend to just trace the leads and then Ohms test them...besides, I don't understand things that you can't look at.

 

[slickerthanyou]

Might be running too rich then.

Just needs to get the air out! A good Vaccum job maybe?

I'm no good with electrical, since getting bitten a few too many times, I tend to just trace the leads and then Ohms test them...besides, I don't understand things that you can't look at.

So you don't understand me, since "you can't see me", My John Cena quote of the day! B)

 

[slickerthanyou]

Ok, update i un-jumpered the tors and the quad would not start, jumpered just one of the tors connections, starts but no revving idles sh*tty, jumpered both tors same results, jumpered parking brake no change, connected lights up, no change. drank two beers, scratched head, no change. Time for some electrical troubleshooting....

 

[slickerthanyou]

Ok, pick up coil is good at 21.2Ω and charge/rotor rotation coil is not at 186Ω suppose to be 192-288 so could this be the only issue?


Here is a vid of what it is doing-

 

[sicivicdude]

You mean that drinking two beers made no difference at all?! hard to believe I:I

 

[slickerthanyou]

i told you 2 weeks ago, a 50+ pilot is far to big
45 pilot and your airscrew will respond

oil light and gauge do not have the ability to shut the bike down, it is only an idiot light, if you keep running, she will blow

have you tried a stock coil and wire ??
those nology plug boots are a biotch to get completely onto the plug

and i gotta ask, you have tried new/different plugs ???

Ok, Tried the 48 pilot same result, 42 pilot same result, No different coil and wire, yes another new NGK plug also.

I'm not running it at all bro just starting it up to see if what i change has any effect, so far nothing! Sure does seem electrical. I'm waiting on a response back from the person I bought the stator from, it does have a 1 year warranty! I have a stator but not a five wire....

 

[slickerthanyou]

One good note the stator is under a year warranty! However i don't think that is my problem. If it would stop raining every hour I'd be able to do some work on it!

 

[slickerthanyou]

Progress, swapped in a new coil and wire, same result. It's either the stator, screwed up wiring, or CDI bad.

I went through all the wiring, couldn't find any breaks all wires have continuity even if I wiggle the harness. I have BOTH tors connections soldered, parking brake left unplugged, and all the lighting unplugged.


As before I have tried every combination, from one set of tors soldered to, soldering the parking brake, jumping the brake switches, leaving it all unplugged no solder.

It just has to be the CDI or the stator.