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 Post subject: 81 Fl250 Won't run
PostPosted: Sat Apr 08, 2017 9:50 pm 
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Posts: 7
Spin motor (( Internal Combustion Engine ? )), have spark at black/red wire on CDI (Capacitor Discharge Ignition) unit coming from motor (( Internal Combustion Engine ? )). Also black wire. But nothing coming back out of CDI (Capacitor Discharge Ignition) unit going to coil via the blue/ yellow wire. I have checked all wires, compared to service manual, replaced CDI (Capacitor Discharge Ignition) unit. Still nothing. What am I missing?


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 12:47 am 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 7699
Location: Hope, B.C Canada
Rednartso2 wrote:
Spin motor (( Internal Combustion Engine ? )) (( Internal Combustion Engine ? )), have spark at black/red wire on CDI (Capacitor Discharge Ignition) (Capacitor Discharge Ignition) unit coming from motor (( Internal Combustion Engine ? )) (( Internal Combustion Engine ? )). Also black wire. But nothing coming back out of CDI (Capacitor Discharge Ignition) (Capacitor Discharge Ignition) unit going to coil via the blue/ yellow wire. I have checked all wires, compared to service manual, replaced CDI (Capacitor Discharge Ignition) (Capacitor Discharge Ignition) unit. Still nothing. What am I missing?


I am not an expert on the FL250 or an electrical guy but there must be a pickup coil near the flywheel. Is the gap correct ??


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 12:48 am 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 7699
Location: Hope, B.C Canada
Are you sure your other CDI (Capacitor Discharge Ignition) is good ??
The CDI (Capacitor Discharge Ignition)'s are very reliable but just a thought.

By the way welcome new guy.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 12:52 am 
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Joined: Tue Jan 17, 2012 3:19 am
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Location: Hope, B.C Canada
It's the correct flywheel right ??
All grounds are in good shape at mounting point on frame (not rusted up)??
Try bypassing the kill switch to confirm it is not that. Use a jumper wire on the switch.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 1:06 am 
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Location: Hope, B.C Canada
Here is a little something something I found and will pass on: viewtopic.php?f=63&t=9195


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 1:07 am 
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Location: Hope, B.C Canada
Also look at the very bottom of this page. There are a lot of similar topics to your issue. Click on them and read away. Good luck.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 2:23 pm 
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Have changed CDI (Capacitor Discharge Ignition) with known good unit. When spin motor (( Internal Combustion Engine ? )) and have test light hooked to Black/ red wire from motor (( Internal Combustion Engine ? )) it lights the light. Hook CDI (Capacitor Discharge Ignition) back up and have nothing coming back out of box. Hook test light to kill switch black wire and spin motor (( Internal Combustion Engine ? )), light flashes. Other wire is green which is green so would ground system.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 3:00 pm 
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Location: Hope, B.C Canada
Well according to the wiring diagram I got, the green wire from Engine is not a ground. In the pic below you can see that the green wire from Engine goes into the CDI (Capacitor Discharge Ignition) box. Am I reading this wrong ?? I am not an electrician so may be I am wrong but that's what I see.

EDIT: Never mind your right it is ground. That's why I am not an electrician and why I hate electrical work.


Attachments:
FL250 cdi wiring.jpg
FL250 cdi wiring.jpg [ 50.77 KiB | Viewed 713 times ]
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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 3:04 pm 
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Joined: Tue Jan 17, 2012 3:19 am
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Location: Hope, B.C Canada
I wonder if someone butchered the wiring somewhere and hooked up two colors wrong in a splice job.
Broken wire or connection some place ??
Just had a thought (sometimes that's bad), I read a thread once where the kill switch was working backwards on an FL250. Off was on and ON was off. Just for fun try it.

EDIT: Unplug the kill switch all together to make sure it is not grounding and try it.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 4:35 pm 
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Location: Hope, B.C Canada
The way I see it, it can only be 5 things:
1) CDI (Capacitor Discharge Ignition) unit -- nope you said it was good
2) Kill switch -- unplug it and try
3) Alternator/Generator -- nope you got light
4) Pick up coil not triggering CDI (Capacitor Discharge Ignition) -- possibly
5) Broken wire or butcher job on harness


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 4:49 pm 
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All great ideas. I unhooked all wires except the one from motor (( Internal Combustion Engine ? )) to CDI (Capacitor Discharge Ignition). Wiring looks good but eliminated​it all. I'm wondering now if yes my test light is showing a circuit but is it possible I'm not getting enough juice from the motor (( Internal Combustion Engine ? )) to actually fire the CDI (Capacitor Discharge Ignition) and then coil?


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 9:02 pm 
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Location: Hope, B.C Canada
Rednartso2 wrote:
All great ideas. I unhooked all wires except the one from motor (( Internal Combustion Engine ? )) (( Internal Combustion Engine ? )) to CDI (Capacitor Discharge Ignition) (Capacitor Discharge Ignition). Wiring looks good but eliminated​it all. I'm wondering now if yes my test light is showing a circuit but is it possible I'm not getting enough juice from the motor (( Internal Combustion Engine ? )) (( Internal Combustion Engine ? )) to actually fire the CDI (Capacitor Discharge Ignition) (Capacitor Discharge Ignition) and then coil?


According to that drawing there are two wires sending juice to the CDI (Capacitor Discharge Ignition). Blue/Yellow which would be the trigger and Black/Red for coil juice. One green for ground. These three must be hooked up. If you are getting juice from the Black/Red then the Blue/Yellow must not be triggering the CDI (Capacitor Discharge Ignition). Are you getting light from the Blue/Yellow ??


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 10:07 pm 
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No I'm not. I'm​going to pull flywheel and see what I can see. I should be getting pulse at both correct.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 10:24 pm 
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Location: Hope, B.C Canada
Rednartso2 wrote:
No I'm not. I'm​going to pull flywheel and see what I can see. I should be getting pulse at both correct.


That's what I would think -- pulse at both wires
You may not need to pull flywheel. Check the gap between pulse coil and the flywheel. It should be in the manual. If it is correct then pull flywheel and see if the key is sheared.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 09, 2017 10:58 pm 
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Location: Hope, B.C Canada
I could not find a gap measurement in either of the manuals. So I took apart a spare FL350 Engine and measured the gap between the flywheel and the pulse coil. It came in at .035". So I would say that if you are in that range plus/minus then your golden.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Mon Apr 10, 2017 12:09 am 
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Location: Hope, B.C Canada
Scratch that idea. I think the FL250 has the pulse coil under the flywheel and the FL350 has is on the outside.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sat Apr 22, 2017 5:55 pm 
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Pulled rotor. Cleaned magnets, everything up. Put back together, spun Engine, still no spark at pulse wire. Is there a way to test it?


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sat Apr 22, 2017 6:04 pm 
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Posts: 7699
Location: Hope, B.C Canada
Rednartso2 wrote:
Pulled rotor. Cleaned magnets, everything up. Put back together, spun Engine, still no spark at pulse wire. Is there a way to test it?


I am not an electrician but the way I see it, as long as the ground wire has a clean contact and you spin the flywheel by it, it should cause a spark. If it don't then it's shot. We need an electrical guy like adnoh to chime in here.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Sun Apr 23, 2017 1:46 am 
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Location: Hope, B.C Canada
Hook a multimeter to that wire and see if you are getting any voltage when you spin it over. Will be less than 12v for sure but not really sure what that voltage should be. See if it says anything in the manual about it.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Tue May 30, 2017 4:23 pm 
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Checked ohms compared to manual. Exciter coil is 215. Pulse coil is 45. Spun motor (( Internal Combustion Engine ? )) with drill and volt meter hooked to pulse wire and did show a couple bolts. Going to mount it all back into the buggy and hook back up. I've changed everything. I've checked everything. If I don't get spark now it might be for sale.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Tue May 30, 2017 6:21 pm 
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Location: Hope, B.C Canada
This might sound really stupid but is there a ground wire attached to the Engine ??
I say this because the Engine has rubber mounts and no way for sparkplug to ground unless there is some kind of wire to ground.


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 Post subject: Re: 81 Fl250 Won't run
PostPosted: Tue May 30, 2017 7:19 pm 
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Not stupid at all. I added a wire from the motor (( Internal Combustion Engine ? )) to the frame. Has the ground wire in the harness that hooks to the coil and one that bolts to roll cage. I'm baffled.


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