I have a 2005 Hammerhead twister jr. 150cc. I have replaced the entire electrical system and still cannot generate a spark to the plug. I have ot be missing something simple and obvious, I hope. anybody have any suggestions?

make sure your coil is very tight to the plug make sure you hear a "click" when you put it on

welcome to buggynews, also check the wires coming from the stator. and the voltage. there is a pick up coil inside there that sends a signal up to the cdi

I have checked the and changed the stator and the associated wires. I can get 3 volts out of the stator wire while cranking and .1 volt out of the trigger wire while cranking. There is not an adjustment on the fly wheel to the trigger pick up so I cant change the gap there.

ok, double check the kill switch and the igntion switch. if either one is bad it wont start.

You can't verify that the stator ignition power winding is OK by measuring it while hooked up to the CDI. This is because the CDI yanks it around severely. Worse, different brand CDI's yank it around differently. Also, if the kill switch wiring is grounded then on some CDI's the ignition power winding on the stator is nearly shorted out.

Three volts (i assume you are measuring the ignition power winding) is way too low. It should be more like 60 volts (disconnected from the CDI). But again, measuring while hooked up to the CDI is meaningless in terms of identifying the source of the problem.

What is the voltage on the kill switch connection at the CDI? It should be huge. Exactly what voltage depends on your meter and the brand of CDI, but it should have a DC component around 50 volts, and a large AC component as well. If it is zero volts then your right at the problem (wiring).

I have waveform drawings of all the CDI / stator / ignition voltages as measured by an oscilloscope, measured on two different brand fully working CDI's. It is really striking how different they are from one another. Even if you don't have an oscilloscope it helps to see what they look like so you can interpret the readings you get on a voltmeter.

I can post these waveforms as jpegs if anyone is interested, though not this morning - I'm late for work!

Wow Lynnedwards.... sounds like you really know your stuff. Where have you been up to now? We could really use your input! What kind of buggy do you ride?

how can I check to make sure I wired my ignition properly?

Follow these links for additional reference material:

http://spiderboxperformance.com/

http://www.buggydepot.com/buggy-tech-center/

You should be getting at least 45 VAC out of the stator for powering the CDI. Unplug the CDI (plug with the black wire w/red stripe). Set a voltmeter to AC and measure from the plug to ground (engine case) while someone cranks the engine. Also you can check the KILL signal wire to CDI (black wire w/white stripe). From the end of the plug, do a continuity test to the engine block, while toggling the key and kill switch. If the kill wire is constantly grounded, then you'll never get a spark.

OK, I have replaced the entire wire harness, ignition, CDI,Rectifier, stator and trigger wire, and the coil wire. While cranking the motor I get better than 100v out of the stator and only .1 v out of the trigger wire. my understanding is that if I dont have a good V meter then .1 would be hard to read accurately, i dont know for sure. I stll cannot get a spark generated.

Did you check those kill and ignition switches?

The black white wire at the CDI while plugged into the CDI has continuity while the ignition is in the off position and while in the run position.

have you tried just unplugging the kill switch to see if you get fire to spark plug and it will start.
on the ignition switch is it a three wire switch and if so is it numbered.
also what color are the wires going to ignition switch.

pud

I have unplugged the kill switch and I still cant get spark, as far as the ignition ,it is 3 prong numbered I, II, III. I have the red wire on teh II , green on the I, and green w/ white stripe on the III. It has to be grounding out somewhere, its almost like the wires are connected wrong, but the harness comes w/ plugs and they can only go in one place. Gremlins in the Kart, I hate em.

i think this might be your problem.
if the red wire is hot,it goes on number 3
i think green is ground so it should go no.1
see if you have a green white stripe wire coming out of cdi?? if so it goes on no.2.
check this out and get back with us.
pud

have you got it running yet??? or have the gremlins gotten the better of you

don't give them gremlins any water or they will multiply and get mean and nasty
yes i saw i the movie a long long time ago,dang that makes me feel old


pud

Man I feel your pain...or at least my friend Dave does. his HH150 is doing the exact same thing. He replaced the ignition switch,and now can't even get his to turn over. Before it would crank but now spark,now nothing with a fully charged battery. He's thinking he might be able to fix it with a match and some gasoline . If you figure it let us/me know before it's to late .

Mike

Well guys I just got from riding and saw this post and wanted to add my 2 cents.Had no problems all day this time parked the buggy to bs went back and it wont start wouldnt even turn over.I run the uni/ steel intake pipe well with all the bouncing around my starter terminal was rubbing snorting out on the frame.Just something to look at!

You need to try plastic . I hope you got it fixed!