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Dunner

1998 TRX 400 No Spark Issue

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Hello Folks - Looking for some help to get my '98 TRX400 going again. I've done lots of digging and reading of other forum posts and still haven't figured it out. I'd appreciate any help along the way as I'm not very familiar with these units.

I received this last year in non-running condition. The previous owner had experienced a bunch of electrical issues and asked if I was interested in it as a project. I accepted the challenge. This thing has been well loved, likely has been swamped a time or two, but I'm optimistic I can bring it back to life and hopefully have some fun with the kids.

From what he tells me, he first noticed that he was blowing light bulbs while riding (head lights, shift indicator lights etc.), but continued to use it without investigating further. Then soon after that the battery went flat, but he could still get it going with the pull start, until eventually it just wouldn't start at all. It's at this point that it got rolled across the road from his garage into mine.

I don't have a proper battery for it, but have been using a car battery and jumper leads to crank it over and check spark by grounding the plug to the cylinder head. There is no spark except for an occasional, very weak, zap just as i'm lifting off the starter button. This was tested with a brand new plug.

Next I turned to the Stator by pulling the plug off the rectifier and checking resistance between the three yellow wires which checked out within the 0.1 - 1.0 range.

CDI was allegedly replaced by the PO just prior to my receiving the unit. Coil resistance was checked and measures in the normal range.

Checked through the wiring harness looking shorts and bad connections but haven't found anything so far.

I had found this post (Intermittent Spark Issue) and was very excited that it might be as simple as a new rectifier, however after replacing the rectifier I still have no luck. That said, I purchased an off-brand from Amazon, and am considering getting an OEM unit, but wanted to consult here first.
 
Measured 10-20 VAC to the ignition coil leads while cranking the engine. Double checked ignition coil/wire resistance which is good. Still no spark. Wondering next if the crankshaft position sensor is fu-bar or not.

Not sure what to check next. Hoping the wealth of wisdom here can steer me in the right direction. Happy to receive any input! Thanks in advance.
 

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Hi Dunner , welcome to the site

 

Most including myself like to use all OEM parts as those china parts are junk , so first thing I would do is put OEM back in place of aftermarket electrical parts and get a good hot battery -----  

 

Occasional spark when you let up on the starter button is a CDI going bad indicator 

 

Blowing light bulbs makes me think voltage regulator overcharging 

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20 minutes ago, Fishfiles said:

Hi Dunner , welcome to the site

 

Most including myself like to use all OEM parts as those china parts are junk , so first thing I would do is put OEM back in place of aftermarket electrical parts and get a good hot battery -----  

 

Occasional spark when you let up on the starter button is a CDI going bad indicator 

 

Blowing light bulbs makes me think voltage regulator overcharging 

 

Yep, sounds like the regulator fried all the electrical stuff on the bike since he continued using it with an obvious overcharging situation.

 

Replace regulator, and probably CDI with OEM parts.

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Fishfiles and jeepwm69: Thanks to you both for the quick reply.

 

Yeah I had a bad feeling about that china Reg/Rec from the start. Will procure some Honda parts and report back!

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12 minutes ago, Dunner said:

Fishfiles and jeepwm69: Thanks to you both for the quick reply.

 

Yeah I had a bad feeling about that china Reg/Rec from the start. Will procure some Honda parts and report back!

 

See if powersportsnation has what you need.  They will at least stand behind their used electrical parts.

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my money say's not having a battery fried the reg/rec, NEVER, EVER RUN THEM WITH OUT A BATTERY !. stick with oem electrical parts..stay far away from china junk. one thing i have learned in all my years of rebuilding atv's ( honda mostly ), is to have everything...AND I MEAN EVERYTHING !, from the battery to the ignition switch oem, this includes the wire harness, all in good shape. i know some oem parts new will be hard to replace ?, but there is good places that sell used parts that are oem, i'd start replacing all these parts back to oem, then see where ya get ?.

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Looks like PSN is running a 20% off sale if you buy 3 or more parts. using code "saleweek"

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Hey Folks!

 

Managed to source new Genuine Honda parts locally. Swapped in the new Voltage Reg/Rec and CDI along with a fresh battery and what do you know?! We had spark and she fired right up.

 

I'm beyond happy to this resolved and very thankful for the help. Now onto new fuel lines, brakes, wheel bearings, and all the light-bulbs that blew as a result of the over-charge situation 🙂

 

Glad to have this forum available as a resource! I hope this thread helps others who run into similar problems.

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Good deal Dunner !!!

 

Stick around and keep us informed on your repairs and  upgrades 

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