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There are three items that are connected together needed to create spark on your 1997 Honda 4-wheeler, regardless of which model it is.
Before we go through a checklist of these three important parts, look for a black wire with a white stripe that runs to the ignition switch and kill button from the CDI box. Disconnect this wire before it gets to the ignition switch and kill button, then check for spark. The most likely cause is a broken kill switch on the handlebar, or shorted ignition switch. Such a condition grounds this wire and kills the spark.
If this test did not restore the spark, continue reading...
Here is what is required to create a spark.
First, the alternator has one coil which generates a high voltage--about 125 Volts AC for the CDI ignitor box.
Second, there is a pulse voltage generated once every revolution of the engine that goes to the CDI box. This pulse causes the CDI to dump its stored energy from the 125 volt line into the primary of the ignition coil.
Third, If the two connections of the wire that runs from the CDI to the Coil are BOTH SHINY clean, the ignition coil will generate a spark.
If any one of these 3 don't happen, the spark will go away. Of these three, item 3 -- one or two tarnished and/or dirty connectors -- is the most likely cause. Just an added resistance of 0.3 Ohms or more in the CDI to Coil connections will cause the ignition to fail. No other wires have to be this clean.
this is cdi wiring plan. notice wires to coil, kill switch, 2 to magneto and earth the diagram link shows what the wires are. physically look to see which wire on bike goes to ht coil, the kill switch, 2 from magneto and earth or to from earth. hope it helps http://tboltusa.com/store/images/5_wire_Lifan_Wiring_041605_HI.jpg
Could be a wiring problem, Bad CDI unit, Bad Coil, Bad HT lead or a bad spark plug.. first thing to do is to take the spark plug cap off and hold the wire near the engine and see if a spark arcs onto the engine. if it does then its your spark plug or spark plug cap. If that doesnt work get a test lamp and check the voltage to the wire going into the coil, if it flashs the light then the coil is bad. If that doesnt work then it could be a wiring issue, so i would try unplugging the kill switch first. if that gives no joy then its a wire harness or CDI/ Magneto issue. So my next step would be to go to a salvage yard or mechanics with the bike and ask them to test the CDI (by using one they know is good or checking the wires).. they will tell you what the problem is from there. Tell them what you have done so far so they don't waste time.
It sounds like either the cdi has become faulty, or it is imobilised due to either the safety switch on clutch lever, side. Stand, ignition switch, or engine kill switch, the only way to test the cdi is to replace it, some circuit tests on the unit may be possible, but only a new unit will eliminate the fault
you run the positive lead from the cdi to the positive lead on the coil.... then somewhere between the negative lead on the coil and the frame/engine ground you splice in the kill switch.........what that does is breaks the ground when you push the kill switch which then kills the spark to the motor
Start with new spark plugs. Do you see spark? If not, check the side stand kill switch. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it.
Check the fuses. How good is the battery? Is the handlebar kill switch on?
Check the operation of the ignition switch and all kill switches with a volt ohmmeter. Check the wiring harness. Did a wire come unplugged? Are all wires clean and with solid connections? Any abraded or pinched wires? Is the bike in neutral and the neutral light is lit up? If no neutral light, check the neutral switch and neutral switch wire on center casing.
Then, If still no spark, get CDI system and coils checked at the dealers shop.
Do you see spark? If not, check the side stand kill switch. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the side stand kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it.
Is the handlebar kill switch on? Is it shorted out?
Are you getting power to the coils?
Check the fuses. How good is the battery? Try a jump start from your car battery.
Check the operation of the ignition switch and all kill switches with a volt ohmmeter. Check the wiring harness. Did a wire come unplugged? Are all wires clean and with solid connections? Any abraded or pinched wires? Is the bike in neutral and the neutral light is lit up? If no neutral light, check the neutral switch and neutral switch wire on center or side casing. If still no spark, get CDI system and coils checked at the dealers shop.
Check the side stand kill switch if your bike has one. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it. Check the fuses. How good is the battery? Try a jump start from your car battery. Is the handlebar kill switch on? Check the operation of the ignition switch and all kill switches with a volt ohmmeter. Install new spark plug.
If that doesn't do it, check the wiring harness. Did a wire come unplugged? Are all wires clean and with solid connections? Any abraded or pinched wires? Is the bike in neutral and the neutral light is lit up? If no neutral light, check the neutral switch and neutral switch wire on center casing. If still no spark, get CDI system and coils checked at the dealers shop. You can screw up a CDI unit checking it yourself.
For a "no spark" problem with a Hyosung RX125, check:
temporarily disconnect the battery. With the engine on at both the ignition switch and engine kill switch, verify that the green wire to the CDI does not measure 0 ohms to ground;
if it does, check the ignition switch and the engine kill switch;
it it measures anywhere between 50 ~ 500 ohms, then reconnect the battery and check that there is +12 on the orange wire going to the CDI with ignition switch on;
for a pulsating voltage (high ACV) at the white / blue wire coming from the CDI going to the ignition coil;
for a pulsating voltage (low ACV, 0.5VAC) at the green wire coming from the pulser coil going to the CDI; and
of course, check if the CDI (black / white) is connected to the ground.
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