crossfire 150 no spark By 72nova (Read 18,754 times)

[72nova]

Hello to all of you. I want to give a little back ground on my problem. I lost spark on my engine found a burnt wire at the rectifier. So I replaced rectifier, CDI & coil. Still no spark. Lost interest, but I decided to fix it. I ordered a new engine & installed it to find that the stator has one less wire from it that the old engine. They sent a new CDI & coil with engine, but not the same connector as my CDI. Should I get a spark just by cranking the engine over?

[Bashan]

That's a pit bike or buggy isn't it? Still, there's a lot of similarities in the electrical systems with scooters.

• First, do you remember which wire was burnt on the first rectifier? That would probably help determine what went wrong.
  
• Second, the only difference I can think of on the CDI would be if it's AC or DC. If you don't have a battery and it's a kick start it's always an AC. If it has a battery it could be either. Here's a diagram to help you determine if it's AC or DC:
  
  
  
  
  
  
• Third, the AC CDI is wired like this on a scooter:
  
  
  
  
  
  
• Fourth, if you could tell us what the wire configuration and colors are we might be able to tell you what's going on. Since it has one less wire I'm thinking you got a DC set up with no AC feed from the stator. It would have a DC feed from the battery. And yes, if it's hooked up correctly you should get a spark when you crank it. Rich

[72nova]

Thanks for this I will check my wiring & get back to you

[72nova]

Ok the wire that was burnt at the rectifier was white. I am going to try to post some pictures to show what I have on the Kart it came with. I have a picture of the CDI that was sent with new engine ihis picture I posted now works I will do more if needed. The CDI is not the same as I have. Thanks again for your help

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[sprocket]

Looks like a hair ball... certainly nothing like a scooter... you should see if you can source a wiring diagram or manual for that thing...

[Alleyoop]

I would check the wires, that BLACK and WHITE might be the KILLSWITCH which if it is should be where the YELLOW wire is.
Follow that Black and White and see if it goes to the kill switch.
Alleyoop

[sprocket]

Yes...change the black/white and the yellow first, as alley said.

Then

Change/reverse the yellow and the blue wires...

SO..

the top row is blue, yellow, black/white
bottom row is green and red/and black on the far right.

That is IF the yellow is the coil wire and the blue is the trigger wire from the pick-up coil...

[sprocket]

May want to try a buggy website they may have a better take on your problem

www.minibuggy.net/forum/minibuggy-net-lounge/13347-crossfire-150-a.html

[72nova]

No wires have never been changed or swapped. The engine I bought is exactlly the same as the old one. I am going to post a picture of CDI that came with engine. I need to know how or if it can be made to work. If anyone knows to wire it. Thanks again for all of your help

[72nova]

Ok here is the picture of the CDI that came with engine and a picture of the connector fron the stator it has on less wire than the old engine. I have no idea how to wire it Well I cannot get the picture to download I will try another post

[Alleyoop]

Wait a minute your confusing us.

Ok is this what you are saying:
1. The NEW ENGINE stator has FIVE WIRES.
2. The OLD ENGINE stator had SIX WIRES.

One other thing you could do is SWAP out the STATOR from the Old engine so that everything matchs up like before.

Another possiblity is that the STATOR on the new engine is grounded and no green ground wire is needed and you actually GROUND the CDI to the frame.
Alleyoop

[Bashan]

This post is from 72nova on a previous thread dated 1-10-12 but in reference to the same problem. Rich 1-12-12

I have an older Crossfire 150 I lost spark found white wire from stator at the rectifier was burnt & melted. Replaced the rectifier coil and the CDI. Still no spark. I thought the stator was bad. Had no way to test or replace. Bought new complete engine. Installed it still no spark. The engine came with a new CDI but it only has 4 terminals & the one on the kart has 6 terminals. the new engine has only 4 wires from the stator and my old engine has 5 wires. If anyone can help me wire to the new CDI I would be very greatful

[Alleyoop]

OK, so what is the picture of above? is that the OLD SETUP or is that the current setup he has with the NEW ENGINE and no SPARK problem? If that is the NEW ENGINE SETUP then what Sprocket and I said about the wires being in the wrong place would apply.

Most have FIVE wires BUT ONE IS A GROUND, so that leaves 4 that actually do something so my Theory following may be the answer.

If that is HIS OLD SETUP with five wires THEN I Think the new ENGINE stator does NOT NEED a ground wire IT IS SELF GROUNDED and the CDI MUST BE MOUNTED to the frame and GROUNDED.
my .02
Alleyoop

[sprocket]

Without know where the wires go and what their function is we are simply guessing...

The 4 terminal CDIs that come with the replacement engines are DC

Useless...

For your Crossfire...swap the stator from the old engine put it on the new engine

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[Bashan]

Yeah.....what they said! I drew this up so I'm gonna use it. I wired a Bashan 150cc scooter from scratch with an AC CDI so I can show you how I did that. Also, I drew in how a DC CDI would get it's power from the ignition. I don't know if you can apply this to your problem or not. The AC CDI will have a black/red power feed and a blue/something trigger wire. There will be one or two grounds, a yellow/black coil feed, and a black/white killwire. I put all grounds (green) to frame. The killwire grounds out the coil when the ignition is on the off side. The on side energizes the black ignition wire from the red battery wire. The wire colors on your buggy may be meaningless if somebody just grabbed handy wires or maybe buggies are different. The concept remains the same though.

If it's a DC CDI, the power will not come from a red/black stator wire but from the hot black ignition wire. The rectifier/regulator (R/R) on my scooter has this wire arrangement:

The white wire powers the red DC charging wire and the yellow does the AC work. Ground the green to frame, sometimes as the guys said a R/R will ground with it's bolt to the frame. Hope this helps. Rich