Wi foreman 2 Posted May 5, 2020 I have a 1998 TRX 450ES. Problem developed where I do not have a spark the majority of the time. Motor cranks with start switch, Neutral light on. Some times when I release the start switch I will get a spark and motor will fire but won't stay running. This happens approximately 1 out of 4 times when attempting to start. I have tried pull starter....there is no spark at all during pull starting... Has anyone every experienced the same??...if so what was the fix. Any ideas how to fix? Share this post Link to post Share on other sites
AKATV 840 Posted May 5, 2020 (edited) Make sure you have a good battery and sparkplug for starters, if good there, make sure your kill switch is centered and those contacts and key switch contacts are not dirty, if those are good, you can try tapping on the CDI box while cranking or pulling, if spark comes back while tapping, CDI is going out You can buy a new one or get a decent used one on ebay- or you can try refflowing the interior solder joints in oven at 450 for 10 mins then let cool without moving it The solder joints get cracked inside the box from heat/cold/vibration/ and age and reheating will reflow the joints and repair 90% of the time (best to do in oven when wife is not around...............) I have some that are working 12 years after doing that It also might be your voltage regulator going out on you, try checking that out as per the Service Manual If you do not have it, here is the link https://drive.google.com/drive/folders/15eWwngQ5SdlsIfbgpm5ZJWJYBYx3vJ7s Good luck and let us know how it goes Edited May 5, 2020 by AKATV Share this post Link to post Share on other sites
Wi foreman 2 Posted May 5, 2020 Thanks for the input 7 minutes ago, AKATV said: Make sure you have a good battery and sparkplug for starters, if good there, make sure your kill switch is centered and those contacts and key switch contacts are not dirty, if those are good, you can try tapping on the CDI box while cranking or pulling, if spark comes back while tapping, CDI is going out You can buy a new one or get a decent used one on ebay- or you can try refflowing the interior solder joints in oven at 450 for 10 mins then let cool without moving it The solder joints get cracked inside the box from heat/cold/vibration/ and age and reheating will reflow the joints and repair 90% of the time (best to do in oven when wife is not around...............) I have some that are working 12 years after doing that It also might be your voltage regulator going out on you, try checking that out as per the Service Manual If you do not have it, here is the link https://drive.google.com/drive/folders/15eWwngQ5SdlsIfbgpm5ZJWJYBYx3vJ7s Good luck and let us know how it goes Thanks for the input...know spark plug, SP Wire and kill switch are ok...will check the CDI... Share this post Link to post Share on other sites
jeepwm69 7,721 Posted May 5, 2020 1 hour ago, Wi foreman said: Thanks for the input Thanks for the input...know spark plug, SP Wire and kill switch are ok...will check the CDI... Don't use any china parts. Buy OEM. If you can't afford new OEM, buy used OEM from someone like Powersportsnation that is a reputable used parts seller. 1 Share this post Link to post Share on other sites
shadetree 5,969 Posted May 6, 2020 c.d.i. is bad, replace with oem from honda. Share this post Link to post Share on other sites
shadetree 5,969 Posted May 6, 2020 and welcome to the forum. Share this post Link to post Share on other sites
Fishfiles 20,147 Posted May 6, 2020 Welcome to the forums , I would think CDI also Share this post Link to post Share on other sites
Derf40 140 Posted May 6, 2020 Welcome aboard WI, you came to the right place lol 😃 Share this post Link to post Share on other sites
sublime68charger 172 Posted May 6, 2020 Welcome from a fellow wi resident! i have a 02 foreman 450s and a 03 foreman 450es they are great bikes. Share this post Link to post Share on other sites
riverc 1,317 Posted May 6, 2020 Welcome to the forum! Share this post Link to post Share on other sites
Wi foreman 2 Posted May 18, 2020 Update to report... My Honda is at the lake and have not been there to work on it for a few weekends. Was there this last weekend. Spent Saturday morning trouble shooting...and yes from what I can determine looks like a new CDI box is required. Ordered on Saturday afternoon. Should have by this weekend so hopefully we will be off on the trails this week.... Provide an update after the weekend... Thanks for the input from everyone!!! Share this post Link to post Share on other sites
Wheeler 2,527 Posted May 18, 2020 Where did you order it from? OEM Honda? Ricks CDI? or eBay Amazon?? Share this post Link to post Share on other sites
retro 4,072 Posted May 22, 2020 Welcome to ATV Honda! Share this post Link to post Share on other sites
Wi foreman 2 Posted May 22, 2020 On 5/18/2020 at 3:28 PM, Wheeler said: Where did you order it from? OEM Honda? Ricks CDI? or eBay Amazon?? I did purchase an OEM...after installing did not fix the problem. However not sure if I induced a further problem when troubleshooing...thats my saturday project to go back through and verify the reading from the meter off of different components. Share this post Link to post Share on other sites
Wi foreman 2 Posted June 5, 2020 June 5 update... After replacing the CDI and that did not cure the problem. Pulled the multi meter back and checked the wire harness between the CDI and the stature. Found there was a short between the ground and stature wire. Looking into the wiring diagram further discovered they both route into the rectifier. Pulled the Rectifier and metered between the ground and stature wire would plug into...dead short. Ordered and installed a new OEM Honda Rectifier...problem FIXED!!...back up and running. My thanks to all the added ideas on what to check... You guys are great and I am quite happy to be associated with a group...Ride ON!! 2 Share this post Link to post Share on other sites
jeepwm69 7,721 Posted June 5, 2020 32 minutes ago, Wi foreman said: June 5 update... After replacing the CDI and that did not cure the problem. Pulled the multi meter back and checked the wire harness between the CDI and the stature. Found there was a short between the ground and stature wire. Looking into the wiring diagram further discovered they both route into the rectifier. Pulled the Rectifier and metered between the ground and stature wire would plug into...dead short. Ordered and installed a new OEM Honda Rectifier...problem FIXED!!...back up and running. My thanks to all the added ideas on what to check... You guys are great and I am quite happy to be associated with a group...Ride ON!! If you check powersportsnation.com, they usually have used rectifiers cheap, and they stand behind what they sell. Glad you got it fixed! Share this post Link to post Share on other sites
