grizzly 660 has no spark, BUT

20569 Views 29 Replies 9 Participants Last post by Dick69, 12 d ago

1nonlyxfiresp

Discussion Starter · Mar 4, 2012

2005 grizzly 660. Has no spark when you push the button. Only 1 spark when you release it. But, it has full spark with the pull start. Bike also runs great when you get it started...

So far i've changed the stator and pickup, ignition coil and spark plug...

Any other ideas??

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1nonlyxfiresp

Discussion Starter · #2 · Mar 4, 2012

2005 grizzly 660. Has no spark when you push the button. Only 1 spark when you release it. But, it has full spark with the pull start. Bike also runs great when you get it started...

So far i've changed the stator and pickup, ignition coil and spark plug...

Any other ideas??

eclipsemsj

· #3 · Mar 4, 2012

never heard of that wierd that the pull gives spark and the el start dont maby you got a short somewere

Cutlass

· #4 · Mar 4, 2012 (Edited)

Sounds like maybe you have a weak battery or poor connection somewhere. The CDI needs to see battery voltage from the battery through the Main key switch and the Stop switch to enable spark. I'm guessing that while cranking the starter, the voltage drops off enough that the CDI doesn't get what it needs, but when you let off the starter it does for a split second while the engine is still spinning.
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Civicgsr

· #5 · Mar 4, 2012

Cutlass said:
Sounds like maybe you have a weak battery or poor connection somewhere. The CDI needs to see battery voltage from the battery through the Main key switch and the Stop switch to enable spark. I'm guessing that while cranking the starter, the voltage drops off enough that the CDI doesn't get what it needs, but when you let off the starter it does for a split second while the engine is still spinning.
Follow me?

^^^x2 what he said. Clean connections and load test the battery.

RRM707

· #6 · Mar 5, 2012

If it sparks when you pull it, the ignition system works.

If it only sparks when you release the starter button,

your problem is the starter button. Change that switch, you should be fine.

repieces

· #7 · Mar 5, 2012

Sounds like something's grounding out whenever you press the start button...

Civicgsr

· #8 · Mar 5, 2012

Maybe clean the connections on the starter relay. Bad ground there may be causing that

1nonlyxfiresp

Discussion Starter · #9 · Mar 5, 2012

- New battery
- New Stator
- New ignition coil
- New spark plug

Still the same problem... No spark then 1 spark when you depress the button. Once the bike starts and warms up, it seems to start working...

1nonlyxfiresp

Discussion Starter · #10 · Mar 5, 2012

- New battery
- New Stator
- New ignition coil
- New spark plug

Still the same problem... No spark then 1 spark when you depress the button. Once the bike starts and warms up, it seems to start working...

Civicgsr

· #11 · Mar 6, 2012

It really sounds like a ground problem to me.
Under your left side cover there is a bunch of wires there. There is a black ground wire with a bullet connector there. Make sure it's clean and tight.
Follow that to the engine and make sure it's clean and tight.

Ever see an old Toyota car that half the tail lights go out when the brake lights come on? That's a bad ground.
I picture that's what your starter or starter relay is doing to the grounding for your coil.
My two cents.

Cutlass

· #12 · Mar 6, 2012 (Edited)

The service manual says these are the only possibilities for no spark:
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):
Procedure
Check:
1.Fuse (main, ignition)
2.Battery
3.Spark plug
4.Ignition spark gap
5.Spark plug cap resistance
6.Ignition coil resistance
7.Engine stop switch
8.Main switch
9.Pickup coil resistance
10.Charging/rotor rotation direction detection
coil resistance
11.Wiring connection (the entire ignition system)

We can probably eliminate the Battery, spark plug and gap, coil and plug wire cap, pickup coil and charging coil.
We can also eliminate the Main switch and stop switch because if they weren't working, the starter wouldn't crank/spin the motor.
So I'm thinking check the main and ignition fuses for corrosion/poor connections, and every other connection in the ignition system (CDI, Stator, Coil, etc)
Another thought goes along the same thought as Civicgsr, poor ground. The starter draws so much power that it could make a mediocre ground not good enough to allow the ignition system work properly.

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1nonlyxfiresp

Discussion Starter · #13 · Mar 6, 2012

i am baffled on this one...... I am a little hung up on the "warmed up issue" like i said once its warmed up it seems to have steady spark and fires up... That is making me think the problem would be near the heat "engine" make sense??

1nonlyxfiresp

Discussion Starter · #14 · Mar 6, 2012

I just went in the garage and triple checked the ground lead to the engine and the small bullet connect connector along with other connections...

I noticed something else.. When i turn the key on the plug sparks once... turn it back off then back on, same thing. Its sparks once every time you turn the key switch on...??

Cutlass

· #15 · Mar 6, 2012 (Edited)

This is baffling.
A warm engine is easier to start. It'll spin easier so the starter doesn't have to work as hard. Might cause less stress on the rest of the electrical system. Just thinking out loud...not really sure.
The service manual leaves a lot to be desired as far as diagnosis here. not much info. So its time for us to think up our own tests. Do you have a service manual?
At this point, if it was my bike, I'd start measuring voltage and voltage drop at the battery, CDI, or anything else in the ignition circuit while cranking the starter on a cold engine and comparing it to a warmed up start.

1nonlyxfiresp

Discussion Starter · #16 · Mar 7, 2012

What about the keyswitch issue?? Like i said, it sparks once when you turn the key on.... everytime...

??

Cutlass

· #17 · Mar 7, 2012

It could be a clue to something but I'm not sure thats much to worry about. Its possible they all do that. Maybe tomorrow I'll bring my spark tester home with me and see if mine does that.

1nonlyxfiresp

Discussion Starter · #18 · Mar 7, 2012

Heres another test i just did with the new battery... Spark plug pulled out of the engine... 12.6v before cranking.. Then it drop to 11.0v while cranking... Isnt that kind of low??

Could the starter be causing all of my issues?? It seems to turn over the engine quick. But thats doesnt really meen anything i guess... Could be shorting out on the inside somewhere??

Cutlass

· #19 · Mar 7, 2012

11 volts while cranking isn't too bad. Thats normal on a car anyways. I think 9.5 or lower would be a concern. Maybe try that test with the spark plug in.

1nonlyxfiresp

Discussion Starter · #20 · Mar 8, 2012

tried with spark plug installed.... Reading 10.9v while cranking... Good or no good??

CDI maybe?? Could it still be the CDI even if it spareks fine with the pullstart??

Thanks

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