Gy6 No spark will cranking By crossfire150r (Read 5,095 times)

[crossfire150r]

Hello, I need help fixing my crossfire 150r. I have replaced the key switch, coil, cdi and stator. When I try and start it, it will not spark when the key is held to the "start" position with the motor cranking. When I release it to "on" and the motor is still spinning, it will start. Also, when I run a ground jumper wire to the green wire on the cdi #4 it will start normally but the key will not shut it off untill I pull the jumper wire back off. I believe that the #4 is ground, but on mine it is a green wire that runs to one pole of the keyed starter switch. The green wire has good continuity to the key switch to the plug at the cdi. I have checked all of the grounds. This buggy does not have a brake switch. I have unplugged the kill switch. I have read through you tech support and not found a problem like this.
Thanks,
Ron

[sprocket]

Sounds like the wrong ignition switch, or it is wired wrong...

[rob63]

Here`s a link to a Crossfire 150 manual www.buggynuts.com/service%20manuals/CrossFire150%20OWNERSMANUAL.pdf
Have a look at the wiring diagram and double check to make sure all is correct on yours. It seems that in the start key position it`s cutting out that green earth/feed which makes me agree with Sprocket, either faulty/wrong key switch, or wires on the wrong terminals of the switch.

[Bashan]

If I'm seeing this right it's one bizarre wiring set up. This three pole ignition switch has two ground functions. If you look at the dark green arrows, which includes the black on the switch, they eventually end up grounding. You can see the coil ground wire, which is definitely a ground, is contiguous with the ignition black. They meet at the black junction box:

If you hit the kill switch it does your standard ground out on the CDI kill port, but it has nothing to do with the ignition switch. The lighter green arrows show the other ground wire on the ignition that does indeed connect to the ground on the CDI. So why does a jumper make this thing work? Because it provides a ground for the CDI! I think the ignition switch in the run position connects the light green arrowed wire to the dark green arrowed wire and provides a ground for the CDI....so it runs. Turn the switch off, break the ground, and the CDI shuts off=buggy stops.

So what's wrong with the thing? If it will only start when you release the switch, it must be breaking the run position ground to the CDI while in the start position. So I agree with the guys, it's a bad switch or switch wiring IMO. But I'm guessing......this thing is bizarre. Rich

[rob63]

Just noticed from the wiring diagram that if you`ve unplugged your kill switch then even when you turn the ignition switch off you won`t have a feed through the kill wire to the cdi. If you plug in the kill switch again, set it to run and put your jumper lead on. Start the engine then turn ignition to off to see if it cuts the engine. If not then press the kill switch to see if that cuts it out ?
Just wondering if this is some kind of earth to chassis/engine problem ?

[tvnacman]

ask et to ask when he phones home LOL!!!!!!!!!!!!!

John

[crossfire150r]

Just wanted to thank everyone that replied! I was focusing on the electrical components and not the switch and wiring. The switch does function properly and I did hook it up correctly. The problem I found was the black wire ground, that grounds several things on the way to the frame was not grounding the key switch. Somewhere in the loom from the key to the volt regulator(where it finally finds the ground) it had broke. Instead of tearing out the loom that hides inside the frame at different points, I made a ground jumper from the black wire on switch to frame and it works!

[crossfire150r]

Rob63 you win!