2.5L 200 EFI Motor - No Spark

[hayajustin]

Hello All,

I've been fighting this issue for a few weeks now and looking for any input or additional areas to test. Here is a list of all the troubleshooting I have done so far.

Stator test complete
- blue wires measured 185Vdc
- red wires measured 35Vdc
- resistance measurements for each were good as well

Trigger test complete
- each wire to ground measured 1.2-1.3Vdc
- black sleeve to yellow sleeve wires measured 3.8-3.9Vdc
- I did switch out the trigger assembly with a new spare I had from my 2.4 motor and the results were the same, so I switched back

VST is powering on and fuel delivery is good

Power to each coil is measuring 120-125Vdc, and it should be 180-200Vdc. I switched out coils from my 2.4 motor and the results were the same. I knew this step was a long shot, but I was frustrated at this point and wanted to do something.

Switchboxes were both replaced a few hours ago.

Black/Yellow wire to switchboxes measures zero with key off, but measure 1.5Vdc with key on and here is where I have a concern. I believe this should read battery voltage with key on.

[Whaaaaat]

Did you try with black/yellow stripe disconnected? Without checking I want to say that wire is ground when key off, kill in disconnect, or in gear, when in run it should be open circuit. Don't think it's ever positive voltage. Again only about 90% on this.

[hayajustin]

I got the motor running today. I wired the trigger set of wires to the wrong switchbox (my bad on that one). I'm still only getting 145-150Vdc to the coils, so it is smoking really bad. I cleaned all of the ground wires to the coils and tested the resistance and all wires were 0.2-0.4 ohms.

It will run with the black/yellow wires connected, The circuit does go open with the keyswitch on.

I checked the flywheel magnets to make sure they were not loose and didn't find anything unsual.