Lost fire, help. - Page 2 - Yamaha Raptor Forum
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post #11 of 25 (permalink) Old 09-16-2013, 09:52 PM Thread Starter
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Found the problem! It ended being a cut wire behind the battery. The wires going to the module being the battery have been taking a beating from the battery moving around. One of the wires was totally broke while others were on there way. I stripped the wire back and twisted it together for a temporary fix to see it would start, hit the button and it fired right up. Thanks for all the help!
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post #12 of 25 (permalink) Old 09-16-2013, 10:43 PM
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Lol see following wires helps, still pain in the ass though! Where you from?
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post #13 of 25 (permalink) Old 09-17-2013, 12:41 PM Thread Starter
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Lol see following wires helps, still pain in the ass though! Where you from?
I was happy to find it. LOL

I am in Nashville, TN
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post #14 of 25 (permalink) Old 09-18-2013, 04:22 PM
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Sorry I didn't get to see this one earlier - one of the common issues is battery squashed CDI wires either broken or shorting together - I've mentioned it in at least two other threads in the last week or so.

Good job finding it; now have fun!

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
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post #15 of 25 (permalink) Old 09-18-2013, 07:27 PM Thread Starter
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Sorry I didn't get to see this one earlier - one of the common issues is battery squashed CDI wires either broken or shorting together - I've mentioned it in at least two other threads in the last week or so.

Good job finding it; now have fun!
Thanks for the reply! I was just glad I found the problem and didn't have to start buying parts.
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post #16 of 25 (permalink) Old 09-18-2013, 08:22 PM
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Just as an FYI re the red stator wire...

The stator and CDI's firmware (it is a small computer) used on the 660 hasn't been changed much since the engine was originally used on a kick start motorcycle in, I believe, the early 90's.

The red and red/white stator pair is called the 'rotation direction winding' and was used by the CDI to determine if the engine was turning backwards - which would sometimes happen if the engine kicked back from the compression stroke when kick starting. CDI detection of reverse rotation would prevent spark from occurring.

They didn't change this stuff when they turned the engine into an electric starter for the Raptor - no need to fix it because it was just a feature that wasn't needed anymore. What they didn't realize was that many years down the road, a common failure of the stator was for the red and red/white winding to lose its insulation and short to one of the charge windings - causing the CDI to THINK that the engine was turning backwards... so the software in the CDI turns off the spark! OUCH!

Unplugging the regulator disconnects the three charge windings from everything else, so the short no longer passes any voltage to the CDI and VOILA, spark returns.

So, cutting the red stator wire (if spark has been lost but unplugging the regulator lets spark return) simply removes the false CDI information that the engine is turning in reverse... thereby returning the spark that the CDI had been inhibiting.

An added bonus is that this signal is somehow summed with the pulse coil signal and used to set the reverse RPM limit, when in reverse. Cutting the red wire removes one of the two signals that are added, and so the RPM limit goes way up.

Hope I didn't bore you.
QM

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo

Last edited by QuadManiac; 09-18-2013 at 08:31 PM.
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post #17 of 25 (permalink) Old 09-18-2013, 09:09 PM Thread Starter
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Great info to have, thanks again!
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post #18 of 25 (permalink) Old 09-18-2013, 09:12 PM
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Quote:
Originally Posted by QuadManiac View Post
Just as an FYI re the red stator wire...

The stator and CDI's firmware (it is a small computer) used on the 660 hasn't been changed much since the engine was originally used on a kick start motorcycle in, I believe, the early 90's.

The red and red/white stator pair is called the 'rotation direction winding' and was used by the CDI to determine if the engine was turning backwards - which would sometimes happen if the engine kicked back from the compression stroke when kick starting. CDI detection of reverse rotation would prevent spark from occurring.

They didn't change this stuff when they turned the engine into an electric starter for the Raptor - no need to fix it because it was just a feature that wasn't needed anymore. What they didn't realize was that many years down the road, a common failure of the stator was for the red and red/white winding to lose its insulation and short to one of the charge windings - causing the CDI to THINK that the engine was turning backwards... so the software in the CDI turns off the spark! OUCH!

Unplugging the regulator disconnects the three charge windings from everything else, so the short no longer passes any voltage to the CDI and VOILA, spark returns.

So, cutting the red stator wire (if spark has been lost but unplugging the regulator lets spark return) simply removes the false CDI information that the engine is turning in reverse... thereby returning the spark that the CDI had been inhibiting.

An added bonus is that this signal is somehow summed with the pulse coil signal and used to set the reverse RPM limit, when in reverse. Cut ting the red wire removes one of the two signals that are added, and so the RPM limit goes way up.

Hope I didn't bore you.
QM
You sure did.


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post #19 of 25 (permalink) Old 09-18-2013, 10:48 PM
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You sure did.
Haha!
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post #20 of 25 (permalink) Old 09-19-2013, 12:42 AM
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Those Canadians! So intimidated by real knowledge...

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
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