No spark

[SS109]

That blue wire confuses me. I would really love to know what purpose it serves.

[Bayboy87]

For all those interested here's an update,
Today I am prepping my new source coil is in the mail and should be here in 2 days I actually got the flywheel off and notice something magnificent. Someone did some really good work for me. The magnets look to be in pretty good shape but this source coil is definitely going to need to be replaced. I'll update after install. I can't remember who it was but they were definitely right about having the wrong puller. I bought a kit for different motorcycles and none of them work but I also had a pulley puller and made it work just fine.

[SS109]

Man, both of those coils, and especially the source coil, look rough. Shame the lighting coil is damaged as I bet it would have still worked.

[KDXGarage]

Good job to get it off. The 89 and newer just use an inexpensive puller.

[Bayboy87]

That blue wire confuses me. I would really love to know what purpose it serves.

From the looks of things I might just need that blue wire. It's also confuses me. I really need to get that manual. At this point when I get the source coil in on Thursday I'm just going to wire it in the way that this looks. Please correct me if I'm wrong. I'm wondering since I'm not using the lighting coil if I should leave it or remove it any advice?

[SS109]

Weird seeing the blue wire goes to the source coil. Yeah, I would wire it like the factory did as they had a reason for it. Am I see things correctly in that three wires go to the source coil, white/red, black, and blue?

On the lighting coil, I would just leave it unless you plan on replacing or rewinding it soon. No reason to remove it otherwise.

[Bayboy87]

I think the blue wire might be for signal to the CDI. My only issue with that is I don't have a blue wire from my CDI to hook up to. I have a picture previously posted in this thread of the CDI and the colors of the wires that come out of it. I also just ordered two manuals, one by accident. I will hopefully get educated on the use of this blue wire soon. I'll keep you guys updated thanks again.

[Bayboy87]

Good morning fellas, small update on my bike. I installed the new source coil as well as the the top small coil on the stator and still no spark. I went back to Ricky stator and ordered the set both bottom and top source coils that sandwich together to make one. I must have done something wrong for sure. I use the original source coil I ordered as well as the small upper source coil from the New order and I'm only getting out 25 ohms of resistance and when I kick it over no spark. What's really frustrating is the second time I pulled the flywheel off one of the magnets came off luckily it didn't break. I also spoke with the original owner whom I bought it from and he told me the stator was replaced. So it makes sense to me now why the wires coming from the stator don't match the colored wires going to the CDI. I'm wondering if I can get away with running the new source coil from the second order. In this order it came with the small source coil as well as the big source coil. I'll take pictures when I get home so all this makes sense. Long story short I put in two new source coils top and bottom and now I've got 25 ohms of resistance and no outgoing power. Rough talk to you guys later.

[Slick_Nick]

The “top” coil is your lighting coil, it’s not another source coil. Using the wrong coil there can fry things.

The third wire off of your ignition stator coil is likely the center tap or a separate end tap. Is there continuity to the black wire with no resistance?

Replace the lighting coil it’s damaged and will be shorted.

[Bayboy87]

So I've got continuity or resistance through the black and yellow wire comes out to about 1.7 ohms. I can get my test light to light up when I crank it over. On to your previous statement so I don't need the skinny coil on top of the larger one? Do you think I absolutely have to replace the lighting coil? On this particular stator I actually have four wires. The source coil is the blue and white with a red stripe and the other coil has the black wire and yellow wire.

[SS109]

You only need to replace the lighting coil if you want to power lights. If not, you can leave it be.

[Bayboy87]

SS109 I was reading over previous posts and yes you are seeing things correctly that black wire is coming from the bottom coil and overlaps onto the top smaller coil as a ground. From that same bottom coil comes the blue wire. That same blue wire connects to the top smaller coil. On the other side of that smaller coil is the white wire with the red stripe.

[Bayboy87]

Here is the latest. So I found a CDI for this bike with the blue wire. If I get it then the stator will match the CDI. For now the stator has been rebuilt for ignition. I'd like the be able to hook it up with the one it came with and save myself 200 bucks but also want it to be right. Get back to me when you guys can thanks.

[Bayboy87]

This is a picture of the one that I found with the blue wire on eBay

[KDXGarage]

electrical jigsaw puzle!!

Is the current thinking that you had a 1983 - 1985 stator plate and 1986 - 1988 KDX200 CDI?

You bought a 1986 igniton coil? or did Ricky Stator send you a 1983 - 1985 coil also?

Now you have bought a 1983 - 1988 CDI?

Is the flywheel from earlier or later??

[Bayboy87]

Yes that is my current thinking. I bought the single source coil from Ricky stator. Still no spark. So I thought maybe the top coil was bad also. I then purchased the set of bottom and top together. I assembled per the directions then reinstalled. Only hooking up the black and white with the red stripe. I had 12+ACV coming out before I hooked it to the CDI. I slapped on a new ignition coil for good measure but yet again no spark. I'm taking a break from the project for a few days to clear my mind, reset and relax. I'll then disassemble again and triple check everything. Get back to me when you can with input. Thanks and have a great day.

[Bayboy87]

I also took into consideration what slick_Nick said about having a short since the other coil is damaged. I got one on the way and will be replacing that one as well. That will be a 100% stator overhaul. Hopefully that will do the trick. I'll gladly try and fail until I get this bitch running, till next time. Later

[KDXGarage]

OK, so I did some eBay picture comparisons. I think you have a 1983 - 1985 stator plate. Is that what you have been buying parts for?

I know the CDI was 1986 - 1988.

I assume some previous owner bought that stator plate and put it on. Maybe the rotor broke part and took it all out? Not sure.

1986 - 1988 is "lighting coil on top", apparently. The ignition coil seem to be all wrapped together.



1983 - 1985 is lighting coil on bottom and double stack clearly shown.

[Bayboy87]

So let me get this straight. The picture on the bottom the 1983 to 1985 looks like the one I have on my bike. This is the one that I've been trying to fix. I basically been rebuilding the wrong stator. The silver lining is I still have the original part I bought from Ricky stator for the 1986 stater plate. So I can remove the lighting coil and source coil for the 83 to 85 then install the one for the 86 and wire up accordingly. After that I should be running business as usual right? Once all of that is done my stator will look like the first picture.

[KDXGarage]

Do you have a 1986 - 1988 stator? I am not sure what you have or don't have, but was curious as to what you had to work with.

I was thrown off when you bought a 1983 - 1985 CDI instead of getting your stator to 1986 - 1988 spec.

I am wondering if the angles are the same.