DF200GKA No spark, new stator and cdi are good

[Yamaha247]

I have a DongFang DF200GKA, and I cannot get spark for the life of me. I am pretty mechanically inclined but I have tried everything and am at the point of just ripping the entire harness out and ordering a new one. I have replaced the stator with the pickup coil also, new cdi (same part #) new ignition coil, new spark plug, new battery, new ignition switch, what am I missing? Everything electrical works as should except for getting any kind of spark. The stator is sending power to the cdi for sure via test light and multimeter, but it’s a hit or miss that I get power coming from the cdi to the coil but never from the coil to the plug. And yes the plug is grounded when testing. I’m at my wits end and am sick of trying to figure this thing out by myself i I could use any ideas or information I can at this point. Thanks in advance…

 

[Snaker]

Looks like a GY6 style 150cc?
Early ones had AC ignition, later ones a DC ignition. Have to figure that out.
Assume your talking about no spark but starter turns the engine over ok?
Some had a kill on electric box
I had issues with rain water getting into the back of the ignition switch
Check any fuses

 

[Yamaha247]

Engine turns over perfect, it’s got the GY6 169cc stamped on it… are you talking about the ignition switch on the dash? Because I just replaced that with the factory one. And as far as fuses, there’s just the one glass fuse that goes to the ignition. Didn’t see any in line fuses. I’m just frustrated more than anything at this point. I know that the stator throws out AC and the Cdi converts it to DC but even so, you’d think that it would be throwing power to the wire going to the ignition coil? But there’s wires going towards the rear end by the brake rotor, is that a safety kill switch or something? I hate working on things after someone else did and they rigged **** so I gotta backtrack… but like I said everything electrical is working all except for the cdi throwing spark out to the ignition coil…

 

[Snaker]

Typically CDI's use AC circuitry.
A DC CDI will use a inverter circuit inside the CDI to make AC.
Magneto's make AC.

AC ignition: should be a oddball, maybe two paper wrapped poles on the stator.
That is AC ignition ignition power coil

DC ignition gets power from battery

You have to trace the wires to see where they go.

 

[Yamaha247]

I just tested the ac coming from the stator and exciter coil, confirming that they are both good and are in tolerance. I checked the pickup coil volts going to the cdi, it is good. Nothing. And I mean NOTHING is coming out of the cdi to the ignition coil. Do you think it’s a kill switch or safety switch? I cannot figure this out still after another 4 hours troubleshooting in the garage.

 

[redflash]

seems like time to sharpen your trouble shooting skills with a....beer !

Da Flash

 

[madprofessor]

I can't get the memory of a single strand of wire from a section of stranded wire (maybe 2 dozen strands) in a spark circuit sticking out from under a poorly installed ring terminal at the stranded wire's end connection. That single little fine piece of wire was touching a metal mount out of sight under the ring terminal, and that tiny leak to ground caused the whole circuit to fail, with the spark grounded out just as sure as if you pressed a dead short type killswitch. Caused hours of hair-pulling-out, knuckles-busting bleeding, wirestripper-sudden-to-the-nose bleeding, etc.
When everything you can physically see is working as it should, hunt for what you physically can't see.
NOTE: Short described above was intermittent, only readable while under the load of the starter motor. When static, all read good, like your setup.

 

[Snaker]

You still haven't mentioned if you have traced wires and figured out whether you have a AC or DC ignition.
And even if the stator has a AC ignition power coil, it doesn't necessarily mean the machine is using it.
The stator's AC ignition power coil wire could be unconnected, and a DC ignition is being used.

You can disconnect the kill circuits to assure they aren't the culprits

 

[Yamaha247]

It is the AC one.

 

[Yamaha247]

I have disconnected the kill switch wire going directly into the cdi and then jumped a secondary ground from the ground going to the cdi to the frame. Still nothing spark related…

 

[Snaker]

The folks on scooter forums that cover these things a lot often complain of replacement parts that are junk.
Might have to review that possibility with your new parts.

Your first post pointed towards the coil/sparkplug connection
Try metering your coil
meter resistance between the sparkplug metal body and engine ground
Take the plug boot off and inspect
Maybe snip off the end of the sparkplug wire and redo

 

[Yamaha247]

After tedious hours with the multimeter, the coil and plug wire are good, the stator and pickup coil are good, all within tolerance. It is throwing volts to the cdi, but the cdi isn’t sending the volts to the ignition coil. I triple checked all grounds, all connectors are good and have no broken spots in any wires throughout the harness (yes I checked every single wire on this piece of junk)… I’m ready to just set it on fire and roll it down a hill at this point. It’s been 2 weeks and I’ve never hated Chinese products this much in my life. Lol

 

[madprofessor]

it’s a hit or miss that I get power coming from the cdi to the coil

all except for the cdi throwing spark out to the ignition coil…

NOTHING is coming out of the cdi to the ignition coil.

but the cdi isn’t sending the volts to the ignition coil.

By my count that's at least 4 times you said there's a loss of power after the CDI. Most folks would say that might indicate a bad CDI.

new cdi (same part #)

Where did you acquire that part number? Off the old CDI itself? By kart's model # on Dongfang website? In an aftermarket parts catalog?
Did it come with a lifetime-transferable-free-shipping/return-postage-guarantee, and cost as much as a Cadillac part? I wonder about 3 things;
(1): If the part # was correct, (2): If you were sent the part you ordered, (3): If the part was made by some Chinese manufacturer that considers ramen noodles to be some really great gourmet eating and has never even seen a Cadillac.

 

[Denny]

Sounds like you need a new a/c cdi since you did say it was a/c and you said you had put on a d/c instead.