2002 EC300 no spark - new CDI box ?

[MickIrlEC300]

So with plans of reinstalling a lighting system to get the new (to me) gas gas ec300 on the road I took it apart to see what wiring I was dealing with.
The bike was running when I bought it and was test drove when I got home with it too.

Upon stripping the bike I found a yellow and white coming from the stator, which I assumed would give me power to the loom for lights etc.

Attempting to start the bike to measure the voltage to these wires and the problems start.

No spark from the spark plug at all.
After a lot of digging through the internet and manuals etc.
I have come to the conclusion that the CDI unit is faulty/intermittently working.

Stator measurements
Impulse coil - red/green wires - 98 ohms
Excited coil - black red / red white - 13 ohms
Charge coil - white / yellow - 0.3-0.4 ohms

Only problem I can see with these measurements is that the charge coil is 0.1 ohms above the tolerance set in the manual? Would this cause any issues for spark considering this is not connected to the CDI box and was not connected when it was running.

Next thing I found was that with a spare ignition coil and the original coil that I could get intermittent sparks (very weak) when I had someone move the CDI wires around on the CDI side of the connectors. We could almost move them to bring the spark in and out which is why I?m considering purchasing a new one.
I belled out each wire on the CDI unit using a needle to get as far up the cable before it goes inside the box and all belled out ok.

So my thoughts are stator is good due to resistance measurements
Ignition coil is good due to getting a spark at one stage
CDI box can give a spark but is extremely hard to get it working even with the bike taken apart?

Last thing to note is that there is a kill switch currently not connect as I bought it this way I?m not even sure where this connects to?

Is there anything else I should try before purchasing a CDI box ?
If I am purchasing one, where is the best place for getting parts these days ?
I am based in Dublin Ireland.
Any gas gas dealers in the uk or gasgas gurus who are a longtime dealer/breaker of the original gasgas bikes ?
I am open to any and all advice before I start ordering parts from the internet ?. Thanks in advance.

[webmaster]

http://www.gasgasrider.org/gg-wiring.jpg

This should help.

Make sure you have a good ground connection(s)- clean with no corrosion. I have seen many posts here over the years with this being an issue.

jeff

[MickIrlEC300]

Thanks for the reply.

I have gone through the wiring diagram I have everything wired correctly.
Cleaned all contracts and earths and everything is belling out fine but still no spark.

I am going to order a CDI box. I have found one online on eBay from Wieltronics that seem to have sold quite a few CDI box?s.

Will send update when delivered and if it fits.

[(F5)]

Just a note that you can't actually test a stator with resistance check. You can tell if it is duff, but not if it is good.

Heating it 'may' help weed out a bad one. They use a fine wire for the ignition winding on these generic (also used on ktm) stators. As the insulation degrades wires start shorting together hence reducing charge critically.

They are quite reliable for many years. Until they are not.

If you need one I'd recommend Electrix world, in UK.