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Old 02-22-2020, 08:24 PM
Five603 Five603 is offline
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Default No spark

Iím working on a kasea go kart with the GY6 engine. I had to replace the resistor due to the tabs rusting away. I replaced the plug. It was stored outside.

I checked the spark but it will only spark once or twice but thatís it. Seems to spark just as itís starts to turn over and as the switch is released. Any ideas?
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Old 02-22-2020, 09:14 PM
Karttekk Karttekk is offline
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What resistor did you replace?
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Old 02-22-2020, 09:20 PM
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itsid itsid is offline
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resistor?
What resistor?

Anyways if it doesn't spark reliably (or at all)
you need to check the usual suspects first:
solid ground signal,
good condition spark plug wire and boot
the spark plug itself (you repalced that so that should be fine)
And you could /should also check for user errors
(some engaged killswitch, a start-prevention [brake pedal needs to be depressed to start?] and so on and so forth)

And if that's also all according to the manual.. it's likely a CDI issue
those things unfortunately fail much quicker than one would like.

'sid
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Old 02-22-2020, 09:23 PM
Karttekk Karttekk is offline
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The magneto under the flywheel charges the battery and creates spark. It sends a signal to the CDI to fire the coil/plug. More than likely the CDI but check the connections from the magneto (the wires coming out of the top of the fan cover) in the power box on top of the engine. Bypass any stop switches too by pulling the wires off the switches and jumping them with a paper clip.

https://www.buggydepot.com/tech-cent...uide-no-spark/
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Old 02-22-2020, 09:26 PM
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It’s number 20 on this diagram. The resistor that is.

---------- Post added at 10:26 PM ---------- Previous post was at 10:24 PM ----------

I hate kill switches.

Last edited by itsid; 02-22-2020 at 09:29 PM. Reason: fixed image
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Old 02-22-2020, 09:32 PM
Karttekk Karttekk is offline
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You won't hate kill switches if your kart ever inadvertently goes full throttle and launches and you can push the kill switch to avoid a potential disaster.
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Old 02-22-2020, 09:35 PM
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Aha that's the auto-choke regulating resistor.. it has nothing to do with it sparking or not.. so we can rule that out to be a non matching or defective part causing your issue
it only makes sure the choke never sees a damaging voltage spike.

Well, kill switch hating can cause severe injury or death
a proper working killswitch is a nice thing to have.. ALWAYS!

'sid

most likely parts to be causing this in order of likeliness:
CDI (14), Rectifier(13) and Coil(21)
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Old 02-22-2020, 09:43 PM
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I shouldn’t say kill switch. What I mean are the safety interlocks on everything. Had to rip all the safety lockouts on an old lawnmower and rewire it. I know Ralph Nader would have a cow but it was such a mess I didn’t have much of a choice. I’m not even sure where the safety locks are or if it has any. I’ll to get out my meter and start testing I suppose.

---------- Post added at 10:43 PM ---------- Previous post was at 10:42 PM ----------

I actually will have to install a new kill switch because the old one is missing.
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Old 02-23-2020, 08:38 AM
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I'm working on an American Sportworks Carbide buggy right now with a spark issue. The thing was smoking real bad so I threw a cylinder and piston kit on it. It was always hard to start, I figured it was due to low compression from the worn cylinder. The rings were stuck on the piston, the piston itself had a pretty good scuff mark on it as did the cylinder wall. It still doesn't want to start easily. I clipped my test plug onto bare metal and tried cranking it, I only get one spark then nothing. Changed the stator/magneto since it was rusted from sitting, changed the voltage regulator since the regulator connector was melted and "glued" to the harness and soldered a new end on the harness. Didn't help. Ordered a CDI for it. Good luck with yours. Keep us updated.
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Old 02-23-2020, 08:45 AM
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Both my ATV and 2 of my motorcycles have CDI that you have to ground to kill it. In running position kill switch is simply disconnected and in stop position it connects ground to one of the inputs of CDI.

I find this extremely stupid design?! How do you find out, that your kill switching wiring is damaged? Only in case of emergency when it won't work, won't bring ground to CDI and won't kill the engine.

It should be opposite. In order to run it has to go through connected kill switch.

Is this common?
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Old 02-23-2020, 09:24 AM
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My guess to see if kill switch wiring is bad is to test continuity with a multi-meter. Jump the switch with a wire or paper clip then see if you get a reading on both sides of the wire. More than likely switches fail more often than wiring. You could run test wires temporarily I suppose to bypass the harnesses but that seems rather involved. Wiring on these Chinese machines is a known trouble source.
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Old 02-23-2020, 11:25 AM
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I jumped the kill switch without luck. The parts diagram shows a brake depress switch for the starter spark of which I was unaware. I will have to investigate this.
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Old 02-23-2020, 04:43 PM
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Keep digging, you'll get it. I hooked up both of my stop switches, threw the battery charger on mine & it fired right up. On these ASW karts/buggies, the stop switch wires go on opposite of each other. The engine switch has a green wire on an end lug and a blue wire on a center lug. The dash switch has a blue wire on an end lug and a green wire on a center lug. If you don't have a manual try to find one online. They're a great help.
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Old 02-23-2020, 11:57 PM
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Quote:
Originally Posted by vybrano View Post
... 2 of my motorcycles have CDI that you have to ground to kill it. In running position kill switch is simply disconnected and in stop position it connects ground to one of the inputs of CDI...
You sure?
have you checked with the wiring diagram?

All I've ever had on motorcycles works the exact opposite..
a positive signal on the kill switch in "run position"
on every bike I owned or fixed
I want say on every I rode.. but that'd be a bold claim since I haven't checked at least half of them tbh

So no.. I wouldn't say it's common to have a grounding killswitch.

"engine off" on kickstarting carburetor bikes however MUST ground the ignition coil,
otherwise the engine could always be started.

so the positive signal of the kill switch actually opens a relais
which disconnects ground from the CDI,
with the switch removed or toggled to "off" it cuts the power on the relais and that then snaps back and grounds the CDI/ignition coil.

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Old 02-24-2020, 11:06 PM
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I was metering the cdi. What should the voltage output be? Is it ac or dc output?
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Old 02-25-2020, 06:20 AM
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Old 02-25-2020, 08:14 AM
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DC to answer your question.
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Old 02-27-2020, 04:13 AM
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It was the cdi. Glad I found the gremlin. Thanks for the help!
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