[KurtB69]

Gfs 06 trx450er

Alright so it's abit of a long story so let me get right in it, my gfs quad broke down when we went on a trail ride in July. It's been broken since and I'm absolutely stumped for my skill level on repairing these (my electrical game is weak lol)

Okay so we were riding and when we stopped she shut her bike down after letting it idle a few minutes and I noticed her fan was off (was on when we left) it's direct wired to a switch and the switch was still on but I noticed the fan wasn't on. When I turned the key back on there was absolutely no power to anything so I decided we would head back after bump starting it. We did that and headed back.

About half way it died completely while coming to a stop sign. From there I just gave up and we brought it home to diagnose .

Upon inspection I noticed the little red wire going from the fuse to the rest of the harness was rotted and disconnect, I fixed that and the bike has all power again but no spark. Everything works but the spark. Now this is where my weak electrical game comes in to bite me in the butt. I have no idea how to use a Multi meter to test the components to trace the failure.

Anyway as I have a handful of these 06+ I decided to take the motor out and put it in a bike that I know starts right up. The engine is "freshly" built I put about 30 hours on it before giving it to my gf and she put about 10 on it. Never had any issues with the actual engine but now in a different bike it still has no spark. I assume it's stator related but I don't know how to properly test any components with a Multi meter if someone wouldn't mind helping me out or if anything comes to mind on what I could look into or try it would be much appreciated by me and my gf.

Thanks guys

 

[Ryan94Wright]

It's likley just the Stator.

I think the No Spark is due to the fact that the stator was already on it's way out just so happed to have failed that night coincadencly. Did you recall if it was hard to start prior to going out that night and kind of backfiring as if it was almost firing spark to soon? usually that is a telltalesign on the 06+ TRX450ER's that the staors are on their way out then a lot of people think it's jetting and such.

I am going to say that I'm 100% certain that the Red Wire that was falling apart that goes to the fuse is unrelated. that is just for the Charging System which prior to the Regulator is a totally differnt charging winding on the Stator.


These Stators have a set of 2 differnt 3 Phase windings, The Set of 3 Yellow Wires are what feed the Regulator AC Voltage, then the Regulator converts that AV voltage to 13/14V DC which powers your Lighting/Battery Charging.

Then for the CDI "feed" Power you will notice it has it's own set of 3 wires as well which are Blue, White & Red/Black (unconnected from the lighting windings)

Put your Multimeter on the 200 Ohm Range (most Multimeters have the beep tone on the 200 Ohm Range) But what you wanna do is have the black probe on the Engine Case and the red probe and touch it to each Blue, White and Black/Red you should not hear a beep from the Multimeter OR it should just say "OL" which stand for "Open Line" ...

Remember too, it its really cold outside the readings will be lower, if it's hot outside the readings might be high. SO if you're in a garage or something just make sure it's a decent temp like 60 degrees or so to get accurite readings.



CDI Charge Curcuites

Testing the Red/Black to White wires -
Black Probe touching to the Black/Red wire, and at the same time touching the Red Probe to the White stator wire... you should get a reading on the multimeter of about 35 ohms (and a beep)

Testing Red/Black to Blue wires -
Black Probe to the Black/Red and the Red Probe to the Blue wire.... You should see a Reading of about 25 to 27 ish (and a beep)

Testing Blue to White wires -
Black probe touching the Blue and Red probe touching the White, Should see a reading of about 7 to 9 Ohms (with a beep)




Pick Up Coil -

(Set the multimeter to the 2000 Ohm Range)

Red Probe to the Blue/Yellow and Black Probe to Green wire you should see a reading of around 240 to 250 ohms

 

[KurtB69]

It's likley just the Stator.

I think the No Spark is due to the fact that the stator was already on it's way out just so happed to have failed that night coincadencly. Did you recall if it was hard to start prior to going out that night and kind of backfiring as if it was almost firing spark to soon? usually that is a telltalesign on the 06+ TRX450ER's that the staors are on their way out then a lot of people think it's jetting and such.

I am going to say that I'm 100% certain that the Red Wire that was falling apart that goes to the fuse is unrelated. that is just for the Charging System which prior to the Regulator is a totally differnt charging winding on the Stator.


These Stators have a set of 2 differnt 3 Phase windings, The Set of 3 Yellow Wires are what feed the Regulator AC Voltage, then the Regulator converts that AV voltage to 13/14V DC which powers your Lighting/Battery Charging.

Then for the CDI "feed" Power you will notice it has it's own set of 3 wires as well which are Blue, White & Red/Black (unconnected from the lighting windings)

Put your Multimeter on the 200 Ohm Range (most Multimeters have the beep tone on the 200 Ohm Range) But what you wanna do is have the black probe on the Engine Case and the red probe and touch it to each Blue, White and Black/Red you should not hear a beep from the Multimeter OR it should just say "OL" which stand for "Open Line" ...

Remember too, it its really cold outside the readings will be lower, if it's hot outside the readings might be high. SO if you're in a garage or something just make sure it's a decent temp like 60 degrees or so to get accurite readings.



CDI Charge Curcuites

Testing the Red/Black to White wires -
Black Probe touching to the Black/Red wire, and at the same time touching the Red Probe to the White stator wire... you should get a reading on the multimeter of about 35 ohms (and a beep)

Testing Red/Black to Blue wires -
Black Probe to the Black/Red and the Red Probe to the Blue wire.... You should see a Reading of about 25 to 27 ish (and a beep)

Testing Blue to White wires -
Black probe touching the Blue and Red probe touching the White, Should see a reading of about 7 to 9 Ohms (with a beep)




Pick Up Coil -

(Set the multimeter to the 2000 Ohm Range)

Red Probe to the Blue/Yellow and Black Probe to Green wire you should see a reading of around 240 to 250 ohms

Thank you alot for that detailed response that really helped me understand, I still don't really get the settings on the Multi meter but at least now I know how to use it to test what I need to test. I'll be trying that Friday when I get back home thank you alot

 

[Ryan94Wright]

Thank you alot for that detailed response that really helped me understand, I still don't really get the settings on the Multi meter but at least now I know how to use it to test what I need to test. I'll be trying that Friday when I get back home thank you alot

No Problem. Yeah just reply back on here what what you see and (I or We) will try to guide you through the best we can to figure out what the exact issue is.

 

[KurtB69]

No Problem. Yeah just reply back on here what what you see and (I or We) will try to guide you through the best we can to figure out what the exact issue is.

Little set back with life right now so haven't gotten to it yet but I picked up an extra used stator, doesn't look OEM but I'm going to test them both and see if they're any good. Sitting quads has been haunting me so bad 😅

 

[hoser]

Any updates on getting it going yet?

 

[KurtB69]

Any updates on getting it going yet?

Sadly not, I have been working on a friends engine for spare cash. But I now have about 5 spare stators including the one already in the bike so it should just be a couple hours of swapping and testing the way I was told at the top of this thread. I've been spending alot of my time recently working on other stuff and getting in as much ski time in before the mountains close up. But don't worry I will absolutely come back to this when I'm working on it and I'll keep you guys updated. I really appreciate the help and I feel bad that I haven't been getting into it so i can respond to you guys 😅 sorry lol