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04 Rubicon 500 intermittent spark...

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Hey all, I’ve got an 04 Rubicon 500 with intermittent spark. I’ve been running in circles because of it being intermittent, but now that I put some time into watching the spark (and verifying fuel and compression) I’m fairly confident that’s my issue. I’ve been using the service manual download and the ignition pulse generator assembly is failing the test. Everything else checks out (Connections, fuses, ignition coil, ECM) so I’m going to order one Monday. Has anyone changed one? I know it’s inside the alternator cover beside the stator...but the manual says you have to remove the swing arm to access it. I have the air box removed, and it looks like there may be room without removing swing arm?

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The stator area is a btch to access. If you have the tools, I'd say remove the swing arm. Inspect the seals and bearings while you have it apart 

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I had an intermittent spark issue on mine after I put it together. It was a brand new harness from Honda and before it ever ran 'good' the ignition coil wire to the back of the coil broke inside the sheething. Couldn't see it but could create the miss wiggling it. Found it with a DVOM. 

 

Anyway, just a suggestion. I know I'm late to the game and you said you found the issue back at the stator...but thought I'd throw that learning out there. I also had an issue with that sire to the pickup sensor that the spade connector was loose and had to be tightened down. Previous owner claimed it was Honda, found out later it was a knock off. 

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Great info there, going to try to replace the pulse generator tonight and report back tomorrow. Thanks for the reply I appreciate it!

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Got the cover and stator assembly removed...it is possible to do it without removing the swing arm, but you have to remove the starter and hold the reduction gears clear of the cover to wiggle it around and remove it! I was surprised when I ran into oil behind that cover (started to get worried, but did some reading and found out that’s the way it is supposed to operate) but won’t be able to put it back together until I can get a new seal, and a new o ring for the cover. Probably should have planned ahead a little better, but here I am. 😂

 

Is it ok to use Ultra Black for the grommet where the wiring passes through that cover, or does it need to be Honda Bond? The ignition pulse generator screws had red loctite on them, so I’ll go back with that as well. Thanks again!

 

Also, it may just be me, but the old pulse generator looks a little swollen, and the magnetic part looks pretty worn.

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Good job accessing without removing the swing arm. I think any oil resistant sealant will work fine on that wire grommet 

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you might check for rodent damage, looks like there have been some damage. very well could explain the spark  issue your having, the one thing you don't want, is them chewing on the electrical system. 

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13 hours ago, Tim-ANC said:

Good job accessing without removing the swing arm. I think any oil resistant sealant will work fine on that wire grommet 

Thank you!

 

12 hours ago, _Wilson_™ said:

you might check for rodent damage, looks like there have been some damage. very well could explain the spark  issue your having, the one thing you don't want, is them chewing on the electrical system. 

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I have looked this thing over a bunch and have been surprised to find all the connections clean and dry, and not a single chewed wire on the machine! Like you, I see signs that mice have been around, but I’ll be damned if I’ve seen one or any damage they’ve done. Pretty much exactly like my deer season this year 😂

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good deal, just toss out some moth balls around the shop, or area where the bike is stored, that help keep those critters away, works good on snakes as well. 

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