DF150TKA NO SPARK

[cdmor]

I have a 4 month old DF150TKA. After experiencing, replacing and repairing what I'm sure all owners of these bikes have. I've come to a (non) spark issue. I've replaced both coil and cdi box, yet no spark. Tried bypassing the kill switch, still nothing. So according to checklist I got off this forum, it must be the STATOR... My problem is, what type stator does this engine use. Planning on ordering and replacing myself, however I am ordering the flywheel puller at same time.(27x1 left thread). My hope is that someone knows this exact type for this engine. Thx in advance....

[wiredgeorge]

If the stator is dead, the scoot should still turn over on battery charge until it is exhausted. I would think you could turn the bike over with the starter or even the kick starter and check for AC on the leads out of the stator. If you have AC there, then the regulator/rectifier could be the culprit. Perhaps if you turn the key on and check voltage at the coil (should be nominal 12VDC) would be a good idea. Last, you may want to check the obvious but you did not mention if you had power when you turned the key on... if you don't you may want to check to see if the ground wire off the battery is still connected.

[cdmor]

Thanks for your reply. Sorry about not mentioning that I do have power when I turn the key on. It cranks with starter but when grounding plug against engine, frame, bolts, etc, no spark. I dont have a multimeter and was under the impression that ignition system was only stator, cdi and coil. I wasnt aware of regulator/rectifier. I made an attempt to replace what I thought to be the obvious when it seems there is no is fix when it comes to troubleshooting. I'll get a multimeter and start back at square 1 on the ignition troubleshooting link. Thank you for your reply and help.

[cdmor]

Do you happen to know where the regulator is located on DF150TKA?

[wiredgeorge]

I have no idea but if you look at the wires coming off the stator, they plug into the regulator/rectifier and the wires out of the reg/rec will have one wire going to the battery hot and the other going to the electrical stuff on the bike. Since you have power, this means at least the battery is still holding a charge. Get a multimeter from a place like Harbor Freight (inexpensive) and put the leads on the two AC hot wires coming off your stator. When it cranks you should get AC voltage... not sure of the spec but probably 20 VAC? It is a lot cheaper than replacing everything.

[cdmor]

I'm hoping someone sees this that can offer any help.... As stated before I have power and had no problem charging. I adjusted valves and afterwards no spark. Have replaced spark plugs, coil, cdi, and trigger pickup/pulse coil, still no spark. multimeter on red/black stator wire read 50v, blue/white trigger wire was nothing so I replaced trigger pickup coil. No fire !!! It was running fine only hard to start so I adjusted valves, which I have done before, now I'm on wits end cause only transpo. Please any help is better than where I'm at. Thanks in advance.

[wile]

Regulator/Rectifier has nothing to do with spark, here is your flow to the COIL. It could be the Pickup Coil if you already replaced the CDI and COIL.

Also Check your grounds from battery to frame and Frame to motor. Since you said you adjusted your valves there is usually the Ground Wire that bolts to one of the bolts on the Valve cover Hopefully you forgot to connect the Ground wire back on the valve cover.
Wile

[cdmor]

Thank you for your reply. I have never noticed a ground on the valve cover but will check throughly. Did you notice that I said I just replaced pickup coil also because I recieved no output on multimeter, but recieved 50v from stator?

[wile]

Well 50V from the stator is pretty damn good ususally anything from 20-80 is good. Sorry I missed the pickup coil part. But now with the new Pickup did you check if you got a reading from the pickup.
Question is your CDI AC OR DC if DC it would only have 1 WIRE on the TWO PLUG going to the CDI.
Wile

[wiredgeorge]

Seems to me that if the reg/rec is the component that takes the AC waveform and turns it into a DC waveform of the proper amplitude and DC is what powers the coil, it is a part of the sparking system. The coil isn't powered by the stator directly as the stator makes AC ONLY.

[wile]

Wiredgeorge,
Don't want to argue with you but just look at the Picture. The Stator feeds the CDI directly. To prove it to yourself unplug the R/R and your scooter will start.
If your CDI is DC it will be feed directly from the battery and with those if you have a weak or bad battery your sh!t out of luck.
Wile

[blacktopbob]

If your spark plug wire screws into the cap make sure it's screwed in tight.Make sure it's screwed in to the coil all the way too.Make sure the coil is bolted flat onto the frame.There may be a burr that you should file off so that the metal sleve in the bolt hole of the coil touches the mounting bracket.The metal sleve in bolt hole of the coil may act as a ground.

[blacktopbob]

Oops.Metal sleeve

[wiredgeorge]

If the DC comes directly out of the battery, then the reg/rec is responsible for the battery charging at the correct level. I don't have a wiring diagram for my scoot (Icebear PST150-7) so I will have to look at the wiring next time I pull the pan under the seat.