Electrical Gurus~ I Need Your Help!!!

[meloyelo400]

So I followed this wiring diagram to a "T" on my 2004 450R and im not getting spark. I am fairly good with wiring schematics and what not, and can't seem to figure this one out. Any help from the electrical gurus would be greatly appreciated! I have a HUGE riding trip coming up in 2 weeks and this is all that stands behind me going or not! Here is a little bit to help with the dilemma- When i have the leads on the mulitmeter RED connected to the positive wire that goes into the coil and the black lead to ground and have it on VDC I get a huge spike up to NEGATIVE 24. But when I put the red lead into the spark plug boot it reads nothing. When I pull the kill switch and kick it over again it reads nothing so I know that the kill switch is working. I swapped a different coil in and it did the same thing. Then I tried the same things with my friends identical quad and it red next to nothing when I kicked it over (1.24). The ground posts are bare metal so I know it isnt the ground where the coil bolts to the frame. I am utterly lost and confused. Any help would be greatly appreciated. If someone feels like calling me and talking me through it please feel free.(805)801-5270 ~Eric

[DnB_racing]

unless your meter has a peak hold(min ,max) you wont see any voltage at plug,its to fast for digital multimeter. try the old Phillips screw driver in boot and see if there is a spark
if I were you I would disconnect the teather and try again, the teather grounds out the signal

EDIT:: I just saw you other post! you didnt say you hacked your harness!! you forgot something! do you have a key switch? if not you may need a jumper!

[meloyelo400]

Oops! Forgot to mention I hacked my harness. I figured the diagram would explain that. My bad. I do not have a key switch. I do have a teather kill switch though. I have the Vortex CDI and it has an extra 2 wires for a teather kill switch to be wired in. The highlighted diagram doesnt leave room for a switch. If the diagram is correct then it should be working, but something has to be wrong...

[DnB_racing]

the highlighted drawing is correct!
for the tether it goes between the blk/w wire and green wire on the connector on the right. the stop circuit! that circuit has to be open to run if grounded it doesn't run.
double check your harness to be sure its correct,
the schematic that's highlighted is all the wires you need


I have to ask why did you feel that you had to have a race harness? I made mine a race harness but I do electrical engineering and I have all the tools (soldering gun, dielectric grease, heat shrink)and a full understanding of how to troubleshoot wire schematics, if you dont why did you need less wires they dont weigh much?Im sorry but if you have to ask for help you probably shouldn't have done this!
Ill try to help but without having the harness in front of me Id just be guessing!

[meloyelo400]

I will go tripple check everything right now to make sure it's right and i'll try re locating the tether to the suggested wires.

As far as why i did it~ I did a FUL REBUILD, all motor internals, plastics, graphics, powdercoat, etc and wanted it to look as clean as possible (ie. getting rid of any spare things that wern't needed and wiring was one of those things.) I though I had a good enough understanding to do this, hopefully it is just the tether messing everything up.

[meloyelo400]

So i triple checked every single wire, tested each one for continuity to make sure the connections were good and that they weren't shorting out with the other wires. Everything checked out perfectly. I also tried wiring my tether to the wires that you suggested and it did nothing.

What I am most confused with is why would it be reading such a high reading as it enters the coil, yet be producing nothing as far as spark is concerned?

To simplify the factor of the tether being the problem, the bike should be able to run with JUST the wiring in the diagram correct? As in it will run,but there is no way to electrically shut it off if it is set up exactly as the diagram reads?

[DnB_racing]

remove the teather and make sure that circuit is open, then pull plug wire and try checking to see if you have continuity from the plug boot to ground, it should be clear no continuity, when you put the plug in is the ground, Do you know what I mean its kinda hard to explain?

do you have a peak voltage meter? is so chapter 20 will help with componet testing and will show at what point your loosing your spark

[meloyelo400]

Ok, so I tested the circuit like you said and it is open EXCEPT for the Bu/Y wire at the connector where it plugs into the CDI. It is giving a reading of .122 This is with everything else connected as though it is ready to run, only the connector with the bu/y wire in it removed from the CDI. Is this normal or is this my problem?

As far as having continuity from the plug boot to ground, there is NO CONTINUITY. I am not sure that I understand exactly what you are saying, but there is no continuity.

I do not have a peak voltage meter.

Thank you for all of your help with this, i greatly appreciate it.

[DnB_racing]

see if you can borrow a fluke meter or any good meter with a (min max) voltage reading.that will help you trouble shoot the components

it sounds like your system should run (with no short to ground at your plug wire). the cdi will give different resistance readings I would think the reading your getting is fine, but you should go through your system with the right meter, as the manual shows and it should lead you to the problem.I wish I could help more but I would have to have in front of me to really be able to find problem.sorry

[meloyelo400]

I'm so bummed! I just cant figure it out. It seems like it should run. I just don't get it. Im going to take it to an automotive electrician today, hopefully he can figure it out.If not, I ordered a stock harness last night and it should be here by the end of the week. Thank you again for all your help.

[meloyelo400]

So I took my quad to both an electrical specialist as well as my full time certified mechanic, and neither if them could figure it out. Both said that my wiring job is done exactly as the diagram shows and was done well to top it off. I swapped the CDI as well as the COIL with my buddies bike and that didnt change anything. Then we took voltage readings as it enters the coil and his bike read 1v and mine read 18v!!! Why it is doing this is beyond me. Any ideas? If I cant come up with a solution I am going to just use his entire motor for my trip. but I would love to have mine working.

[DnB_racing]

I was looking over the cut down schematic, and i saw that the cdi isn't grounded, the last wire to the left on the right connector, that might need to be grounded!

Im not sure though, but its worth a try, add a jumper from the green to a motor ground, just a loose wire and give a check,

what do you got to loose?