So we got this 1997 Warrior - another thread we were doing a rebuild.
Before we started the rebuild, it turned over at the handle bar switch and ran with no problem.
Took it down to the frame - painted. All new bearings. Rebuilt the top-end .20 over. Put the motor back in finally.
Hooked up the wiring harness the exact way it was hooked up before. Headlights light, taillight lights. Neutral light indicator doesn't light. Reverse indicator will light if put into reverse.
Hit the start button. Nothing. Clutch switch/kill switch flicks a relay. Tested that relay (the system starting safety relay) ok. Went to test the neutral relay and it's all burnt up looking - when tested it generated a butt load of heat and never triggers. So that's on the replacement list. But we started before this project so that is what is strange - I think it's always been bad because we had no neutral light before.
So is this the reason for no start button activity?
I jumped the starter solenoid and the bike cranked and fired right up. I shut it off. Adjusted idle/choke again. Fired it back up - let it run for a minute. Shut it off and topped off the oil. After it cooled down - I wanted to fire it up again and it just cranked cranked cranked cranked cranked.
Now it's getting no spark.
I've gone through the entire wiring harness. We're grounding.
I tested everything I could. Neutral Switch (stays ungrounded regardless of gear selected), and neutral relay appear to be bad. The starter, solenoid, switch controls, clutch switch all appear to be functioning. The key and is charging the brown wire. The blue/white and red/white wires going into the solenoid are both charged positive when the kill switch is off - when switched to run they both go to ground.
On the stator. I'm not sure what wires are which on the stator - there are 3 paired wires. I tested the 3 wire white harness that goes to the regulator and all testable pairs are just shy of 1ohm resistance which the manual says OK. I'm not sure about the other two paired wires coming out the stator - one measured 300 and the other measured 600. I'm assuming the 600 is an out of spec pick-up coil? Which might answer the no spark?
Also the CDI box looks like it's been heated up too much and has peddles melted into it. There is also a hole in it as well. And I can see the top of a capacitor melting through.
So right now. I'm nearly thinking we need a new stator, CDI, neutral switch and neutral relay.
Seriously... What the hell?
Before we started the rebuild, it turned over at the handle bar switch and ran with no problem.
Took it down to the frame - painted. All new bearings. Rebuilt the top-end .20 over. Put the motor back in finally.
Hooked up the wiring harness the exact way it was hooked up before. Headlights light, taillight lights. Neutral light indicator doesn't light. Reverse indicator will light if put into reverse.
Hit the start button. Nothing. Clutch switch/kill switch flicks a relay. Tested that relay (the system starting safety relay) ok. Went to test the neutral relay and it's all burnt up looking - when tested it generated a butt load of heat and never triggers. So that's on the replacement list. But we started before this project so that is what is strange - I think it's always been bad because we had no neutral light before.
So is this the reason for no start button activity?
I jumped the starter solenoid and the bike cranked and fired right up. I shut it off. Adjusted idle/choke again. Fired it back up - let it run for a minute. Shut it off and topped off the oil. After it cooled down - I wanted to fire it up again and it just cranked cranked cranked cranked cranked.
Now it's getting no spark.
I've gone through the entire wiring harness. We're grounding.
I tested everything I could. Neutral Switch (stays ungrounded regardless of gear selected), and neutral relay appear to be bad. The starter, solenoid, switch controls, clutch switch all appear to be functioning. The key and is charging the brown wire. The blue/white and red/white wires going into the solenoid are both charged positive when the kill switch is off - when switched to run they both go to ground.
On the stator. I'm not sure what wires are which on the stator - there are 3 paired wires. I tested the 3 wire white harness that goes to the regulator and all testable pairs are just shy of 1ohm resistance which the manual says OK. I'm not sure about the other two paired wires coming out the stator - one measured 300 and the other measured 600. I'm assuming the 600 is an out of spec pick-up coil? Which might answer the no spark?
Also the CDI box looks like it's been heated up too much and has peddles melted into it. There is also a hole in it as well. And I can see the top of a capacitor melting through.
So right now. I'm nearly thinking we need a new stator, CDI, neutral switch and neutral relay.
Seriously... What the hell?