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IGNITION TROUBLESHOOTING GUIDE: NO SPARK? [126,548 views]
 

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Ignition Troubleshooting Guide: No Spark?
[126,548 views - 109 comments - Rating 4/5 ****- ]

LAST UPDATED: 10/8/2011

See Attachment: Yerf Dog GX150 Wiring Diagram

To accurately diagnose your ignition system, you will need to do each of these steps in sequence. Start with step 1 and work through this guide completely.

This guide was originally written for the Yerf-Dog GX150, but has been re-written to cover almost any of the 150cc buggies, scooters, or ATV's with the standard "AC" CDI setup.

-----------

The 150cc GY6 ignition system is fairly easy to troubleshoot in the case of malfunction. There are 4 major components that work together to produce spark, if any of these is defective, spark will be lost. What we will be doing here is troubleshooting these ignition parts.

Ignition energy travels along the following path starting at the stator:

--1. Stator (6th winding and trigger pickup module)
--2. CDI unit
--3. Ignition coil
--4. Spark plug


First, bypassing your switches



A very common cause of no spark is a defective ignition or kill switch. Before beginning to troubleshoot ignition problems, it is best to bypass the switches. Some GY6 vehicles like the Yerf Dog GX150 have only one switch, but most others have two. The bypass process is the same.

Bypassing the switches
1. Reference this pinout diagram.
2. Create a jumper wire from pin #4 directly to a good grounding spot on the engine.
2. Remove the #5 wire from the CDI plug at the harness. This can be done with a sharp narrow tool like an ice pick or stiff paper clip. Looking from the front of the plug, you will see small metal tabs on each pin which secure them to the plug. Push the tab down and the pin will release. Be careful not to break the plug or pin.

Stator (Ignition winding and trigger pickup module)

Ignition winding: Depending on your stator type, you have either 6, 8, or 11 windings. Of these windings, one is dedicated to supplying the CDI with ignition power. This winding is usually wrapped in white cloth material and sealed over with clear epoxy.

Trigger pickup: A simple type of crankshaft position sensor. Sends a signal to the CDI to let it know when to send fire to the plug.

Troubleshooting the Stator:
1. Set your multimeter to read in VOLTS "AC".
2. Locate and disconnect the Black/Red and Blue/Yellow wires coming from the stator, where they plug into the main engine harness. (These are both bullet-style connectors)
3. While cranking the engine, use a multimeter to check for voltage coming from the Red/Black (CDI power wire) and the Blue/Yellow (trigger wire) coming from stator. Place the black lead of multimeter on a metal surface of the engine while using the red lead on the tips of the wires.
4. There should be between 20vAC ~ 100vAC coming from the CDI power wire (Black/Red), although much lower voltages will still be able to produce spark.
5. There should be at least 0.05vAC coming from the trigger wire (Blue/Yellow).
6. Write the voltages down and continue to the next step.

Normal values:
Stator output: 20vAC minimum.
Trigger output: 0.05vAC minimum.

The CDI Unit
The CDI unit is powered by the AC current coming from the wrapped stator winding. This current is stored in a capacitor within the CDI unit. When a signal is received by the trigger pickup passing over the flywheel magnet, the CDI will discharge the stored energy into the wires leading to the ignition coil.

Troubleshooting the CDI:
1. Ensure your multimeter is set to read in VOLTS "AC".
2. Just like before: while cranking the engine, use a multimeter to check for voltage at the two primary wires of the ignition coil. Connect your back multimeter lead to the black ground wire at the coil, and with the red lead to the lighter color wire (usually blue or purple, but it varies). At this step we are checking to see exactly what the CDI is outputting. Write the voltages down and continue to the next step.

Normal values:
CDI output: Can be 5% to 30% less than the output from the stator. The minimum we have seen working is around 18vAC.
The Ignition Coil
The function of the ignition coil is to multiply the voltage of the power supplied from the CDI, and to send the multiplied power to the spark plug.

Troubleshooting the Ignition Coil:
Check for 0.1 ohm ~ 1.0 ohm across the two primary coil terminals. This isn't exactly definitive, as we have seen working coils with 0.0ohms resistance. The best way to tell if the coil is bad is to perform steps the steps above. If there is still no spark, the coil is likely bad.
The Spark Plug

The plug is very rarely the cause of no spark on the GY6. If the plug is fouled or cracked it may not spark. Ensure that the spark plug is gapped properly.

Recommended spark plug gap: 0.6mm ~ 0.7mm (0.23" ~ 0.27")

This article has been downloaded 126,548 times
109 comments about this article:
Poster #1 [03/03/10]
Just what is the proper/optimum spark plug gap for the 150cc?
Poster #2 [04/21/10] Rating 4/5 ****-
I have gone through your checks for a non-firing gy6 150cc engine. I have replaced the coil and cdi once and the stator twice. Checking the pick up on all three the best voltage i get is 0.25vAC. The voltage I have from the 6th wire is up to 140vAC. All of the other readfings are within your specs. Do you have any other ideas before I replace the CDI and coil again? Thanks eTa <><
Poster #3 [04/30/10]
I was running my crossfire 150 on jackstands pretty hard shut it off and now it just backfires. Ihave another one so I changed the flywheel and everything under it and it still does the same thing any help would be appreciated!
Poster #4 [05/15/10]
I have no spark either. According to this write up my stator is weak but acceptable at 5-6 volts. I get 0 volts for the trigger wire. So do can I just replace the magnetic pickup for the trigger wire or does that come with a complete new stator?
Poster #5 [05/17/10]
i ran all the steps. just bought an engine upgrade kit. thats the cdi, plug, and stuff. i have replaced the stator. primary coil omhs are reading fine. ihave nothing reading off the blue wire from cdi to coil.
Poster #6 [05/29/10]
i am having the same problem. all the parts have been changed and i still have no spark at all. any other tips to help?
Poster #7 [06/17/10]
I have a Crossfire 150 that will not crank with the switch. the motor turns freely when i cross the selonoid.Can someone tell me which part to change
Poster #8 [06/22/10]
what did u do to fix it??
Poster #9 [06/26/10]
This diagram is not possible.

It would introduce AC to the battery circuit and it doesn't address brake lighting. Further, the black lead from the stator tests with AC voltage against ground, so it cannot be connected directly to ground. I need to find a correct wiring diagram, particularly as it pertains to the stator and rectifier/regulator. Thanks for trying though.
Poster #10 [Travis @ BD-ORB] [07/06/10]
This is the original Yerf Dog GX150 wiring diagram from the service manual. It is accurate, please take another look.

@Poster #9, what buggy or scooter do you have? Perhaps I can source or create a diagram specifically for your purposes.
Poster #11 [08/12/10]
I am having the same problem as poster #6. Did he ever get it going, if so what was the problem?
Poster #12 [08/23/10] Rating 4/5 ****-
I followed your troubleshooting procedures, I was able to figure out that the coil was bad. I bought a brand new coil & replaced it, before I replaced it I checked the resistance(ohms) on the new coil & I still got 0.00 ohms across the primary coil leads. I replaced the coil anyway & the motor ran great, ran at two different times(different days) with no problem(the battery was dead at the time & started with a battery charger. When I changed the battery before starting the third time after changing the coil, the motor would not start. All checks are correct again per this troubleshooting guide except for the primary coil resistance which is still 0.00 ohms resistance. Why is the coil going bad? This is a 150 CC motor on a Carter Talon. The voltage coming from the 6th stator winding is reading 130 VAC, but I don't see this causing any issue? Any help at all?
Poster #13 [08/30/10]
I replaced my CDI and ignition switch. I cant get the kart to start? When I bypass the button and jump the coil she turns over but won't start? I don't get it? Its got compression, spark, but no go?
Poster #14 [09/15/10]
I have a GX150 with a spark issue. I have spark for the first revolution when starting but nothing past the first revolution. Any thoughts on what would allow this to happen? Thanks in advance for your help.
Poster #15 [10/12/10]
i have the same problem, spark somtimes and then nothing. when i turn off the ignition switch quickly i get one spark...any ideas...anyone??? brillacontracting@yahoo.com thanks
Poster #16 [10/28/10] Rating 5/5 *****
HAD SAME ISSUE AS POSTER 14 AND 15. TRACED BLACK RED FROM STATOR, FOUND COUPLING BELOW POSITION OF CDI HAD COME LOOSE!
Poster #17 [11/07/10]
i have NOOO spark on my GY6 (yerf-dog 3206). I replaced the coil as well as the CDI. I was told it might be the stator, but i don't know where the stator is. Please let me know what you think. Please e-mail me instead of posting on her due to not having acess to a computer often. I get E-mails to my phone. Peiferlawncare@aim.com Thanks alot, very appreciated!
Poster #18 [11/27/10]
My ba150 baja blows my cdi up. Why?
Poster #19 [12/03/10]
to fix the ignition swith try replacing the fuse in the electrical box
Poster #20 [12/17/10]
how to rewire the howhit engine?
Poster #21 [12/23/10] Rating 3/5 ***--
All this and still no spark
Poster #22 [12/29/10]
Sometimes i get spark but other times i dont get any spark. Why?
Poster #23 [12/29/10] Rating 4/5 ****-
Rating:4/5
Poster #24 [01/16/11]
what would cause a retifier to burnout/meltdown?
Poster #25 [01/22/11]
Before I did these tests, I've replaced the coil, the CDI twice, and the sparkplug. Battery reads 12.3V, the DC motor spins when power is on. Tail lights turn on. However, the sparkplug refuses to spark. I have a 50CC GY6 bike.


The resistance between the black/red wire from the stator to ground is 462ohm.

While cranking, I get 55V AC between ground and the black/red wire from the stator.

While cranking, I get 0.08V AC between ground and the trigger wire from the stator, but only for a fraction of a second. It then drops to 0V after that. Is that right?

While cranking, I always get 0V AC between the two black and green connections on the wire coil (that connects to the spark plug). The resistance between the two is about ~0.2 ohms.

With the ignition kill switch in the ON position, the resistance between ground and the black/white kill switch wire is infinity. When in the OFF position, it is about 0.1ohms.

I didn't yet remove the ignition kill switch wire, should I try this? It's 23F outside and I'm freezing my knickers off lol . . .
Poster #26 [01/22/11]
got a compression but have no spark i dont have a kill switch help i smell gas on the spark plug is that normal?
Poster #27 [01/28/11]
I followed your troubleshooting procedures, I was able to figure out that the coil was bad. I bought a brand new coil & replaced it, before I replaced it I checked the resistance(ohms) on the new coil & I still got 0.00 ohms across the primary coil leads. I replaced the coil anyway & the motor ran great, ran at two different times(different days) with no problem(the battery was dead at the time & started with a battery charger. When I changed the battery before starting the third time after changing the coil, the motor would not start. All checks are correct again per this troubleshooting guide except for the primary coil resistance which is still 0.00 ohms resistance. Why is the coil going bad? This is a 150 CC motor on a Carter Talon. The voltage coming from the 6th stator winding is reading 130 VAC, but I don't see this causing any issue? Any help at all?
Poster #28 [01/28/11]
I have a gy6 150 cc scooter that I replaced the front forks tire and handlebars. I went to fire it up and noticed the 2 little wires that come out from the push button starter now are plugged in to nothing and I cant for the life of me remember where they go. I thought I had labeled and color coded everything as it came apart. Please help :-(
Poster #29 [01/29/11]
I have a american sportsworks dune buggy 150cc engine. I have changed the sparks plug, coil, cdi, cleaned out the carb. and I still can not get it to stay on. I will every once in a while get it to turn over but always dies on me. Could this be a bad battery? My ignition was left on and drained the battery.
Poster #30 [02/03/11] Rating 4/5 ****-
I have a gy6 150cc engine on the yerf dog 3206, I bought it with an aftermarket cdi on it which I think went bad after I drove it a few times, the spark plug lost it's spark. I put on the stock cdi that I got with it and it sparked the plug, but when the engine is started and you give it gas it will backfire from the carb and just stall so I bought a brand new aftermarket cdi and it wouldn't spark the plug. Although I did see a very small spark once and awhile, it's nothing like the spark I get from stock cdi. I have no idea what the problem could be. if anyone has a suggestion my email is becker0304@hotmail.com
Poster #31 [02/16/11]
i have a 150cc i can start bike by jumping theselinoid. but to start with ignition key ,no reaction ,but while running i have headlight and tailight,no turn signals ,no horn, but,kill switch works, what do you think?
Poster #32 [02/28/11]
No spark on Howhit 15cc. Replaced all components with BDX replacement CDI, coil solenoid. Still no spark. Turns over fine.

Just received replacement wiring harness. Plugged in - NOTHING. Are some wires different? Please help! I am SO CLOSE to getting this thing running.
Poster #33 [03/07/11]
On my stator on my trigger wire i have a 0.2 but noticed oil on the stator. Would this cause me not to have a 0.5 min output. If i cleaned my stator of oil would this help me. I am in the process of changing my gaskets to prevent any more oil to enter my stator area.
Poster #34 [03/08/11]
On my stator my trigger wire at first shows .06 on the first turns and jumps down to .02 is this normal or do i need a new stator
Poster #35 [03/19/11]
poster #14 here, i have solved the problem on my carter bros. talon 150, similar to or the same as many other gt or gx models out there, they are all made by the same company and have different company logos. that being said, you can find just about any part you need on line, i started with the ground, very important that all ground wires are clean and have a solid connection. alot of this stuff is mounted on rubber mounts, plastic spacers and washers etc. grounds must be solid. next the coil, coils are deceiving, they look great and may even test out good, however under load they loose thier ability. there is a small electrode located in the sparkplug cap, remove the small brass screw inside to find a small spring and a carbon eletrode. mine was burnt and cracked causing a reduction in the spark i could get. evidentally that is in place to intensify spark. that was my second problem after ground. and last but not least was my cdi box. i have learned from all my backyard mechanic mentors that an electronic box be it a a cdi, stator, resitor or what ever will either work or not, there
is no in between. that is not true any longer. we have to think todays technology, different materials, conductors, etc. can produce many different failures. the good news is that they are cheap! i just wanted to share some of my findings hope it helps someone, good luck and have a safe summer 2011
Poster #36 [04/02/11]
I am working on a helix 150 and it has a dc cdi on it wold it be the same
Poster #37 [04/11/11]
poster number 14/35- i have the talon 150 as well, no spark, what plug do you run in yours?
Poster #38 [04/29/11]
Travis, I've read almost all the comments here and I can tell you that I'm in the same problem, have changed: stator, cdi, ign.coil & RR, I'm still having no spark, I'm really disappointed, my e-mail is hespinoza41@yahoo.com.mx, Can you give me some ideas to success?
Poster #39 [06/02/11]
I have three old ignition coils including the one on my 150CC Tank moped that will not start, along with three more spark plugs and one brand new ignition coil. I have tried all combinations of these items and am still not getting a spark while holding the spark plug against the engine block. The battery is dead, but I have a engine starter/battery charger that allows the bike to crank. When it cranks, everything sounds fine except it won't start. The only other weird issue is that after about five or ten seconds, all the power to the bike shuts off for a few seconds. The starter/charger seems fine so it seems like the shutoff problem is with the bike. Any ideas? Thanks for your help.
Poster #40 [06/06/11]
I have the. Same problem. As post #38 what the answer
Poster #41 [06/22/11]
Had the same issue. no spark. replaced coil, bypassed kill switch, plug, cdi, stator still no fire. ran a new ground(GREEN WIRE) to cdi (see pinout chart) SPARK SPARK.....
so rehooked kill switch and put on a new push to start switch (2 wire left green off.)and ran an new groung to the frame for the cdi.
So the buggie is up and running...
I bypassed the ign switch early on and no spark. so must be a broken wire in the harness to the front.
GOOD LUCK ALL....
Todd
Poster #42 [06/29/11]
just had bad time with 150cc scooter no spark the kick stand on some of them has a kill switch if its down it wont start just spent 5 hours on no spark and then put kick stand bam it started
Poster #43 [07/16/11]
well i spent two hours of troubleshooting and swapping parts using this procedure. After getting very frustrated and walking away for a little while, I came back and found I forgot to flip the kill switch back on! Feel really dumb right now!! I guess I skipped the first step in this procedure to check or jumper those switches out!!
Poster #44 [08/01/11] Rating 4/5 ****-
Consider the type of spark plug as well.
I chanced into a Bosch Platinum spark plug.
They have a high internal resistance and cannot be used in combination with a series resistance in the spark plug cap.
There's a weak spark, but you only can see'm in the dark.
On the metal bodies of these plugs most often there is a "R" in the number.
Upon that I found a clogged idle fuel adjusting screw passage as the reason for the starting problems.

Poster #45 [08/05/11]
I HAVE REPLACED EVERYTHING ELECTRICAL INCLUDING THE WIRING HARNESS AND STILL NO SPARK WHAT THE HECK ANY SUGGESTIONS.
Poster #46 [08/08/11]
when i kick start the 150cc CDI ignition 2 stroke engine of scooter, it starts for 2-3 seconds & stops, immediately further kicking it doesn't respond however after a gap of say 20 seconds or more it starts again for only 2-3 seconds & stops. If this process is done for 5-6 times i.e. kicking after a gap of 20 - 25 seconds it starts properly & doesn't stops. It runs well whole day but again in the morning or after a gap of 10-12 hours the same problem persists. Please help me out. Regards Sanjay
Poster #47 [08/14/11]
I am baffled and stumped. I have a yerf dog 150 cc. I have replaced the stator, the CDI, the rectifier, the ignition on/off switch, the battery, the wiring harness, and the coil and plug! I have no spark at all! Tested stator and its fine. Wires are hot at the relay plug when the switch is on although I can't get the kart to turn on from the red push button at the wheel. So I jump the relay poles like everyone else. No spark anywhere. I tested the stater and its good. Its getting power to all the switches everywhere, but no spark to ignition and the push switch doesn't trigger the starter so I bypassed the brake and still no action at the push button. Full of gas with new carb too. I could have just bought a new one at this point. Anybody have any idea what this is other than I am terrible at trouble shooting electrical parts? I follow every diagnostic on here and Im getting nowhere. I did notice that there where some low readings on the meter between the CDI and Coil, but what the heck could it be its a Hi Performance CDI TOO! NEW HARNESS? CMON HERE?
Poster #48 [09/12/11]
need the color code for a GY6 150CC volt reg it is a 4 pin #1 red #2yellow
#3 white #4 black Thank You Bill
Poster #49 [09/22/11]
how does the cold start or choke work on on the gx150, I cant get it to start with out holding my hand to cover the air filter box to choke it b efore it will start. anyone know? Thank You, Sam
Poster #50 [09/23/11]
I found the problem with the enrichment circuit from advice on other page, thank you all, Sam
Poster #51 [10/03/11]
I would like to know some of the answers that were given to the above posts. I have replaced everything from the harness to the plug. Had spark but wouldn't start - new carb installed..........next day no spark. EVERYTHING is within specs and I have great compression.
Poster #52 [10/05/11]
i put a new battery in my crossfire 150r i also have the ignition straight wired but now all it will do is click at the solenoid it was turnning over untill i tried the new battery

Poster #53 [10/07/11] Rating 5/5 *****
Awesome guide...one typo though...In the Stator troubleshooting, you say "5. There should be at least 0.05vAC coming from the trigger wire (Blue/Yellow)." I think you mean "0.5vAC". Thanks so much for posting this! SUPER HELPFUL!
Poster #54 [10/19/11]
just went nuts on no spark on my 150 yellow cart ended up being my new stator on blue wire. I also replaced every thing good luck
Poster #55 [10/23/11]
i also have a 150r that will not fire and spins freely. i have tried numerous things stator, coil, resistor, spark plugs, battery... just about everything imaginable. im loosing my marbles over this. ive completely torn down and rebuilt the motor. (more or less haha) still wont work. i dont really understand the problem. im a machanic and im stunned i cant figure this out. please help if u can tysm. derick from bama!
Poster #56 [10/23/11]
derick from bama again. we have 5 wires comin from the harness to the switch. colors are yellow,yellow/green, black and a green wire. i would like to hook up a ignition switch with an A & B side. i would to put power to the switch yellow and green. i also need to route in a push button start. yellow and blk is the kill switch. how can i route power from the key switch to the push button and have it all work together. help plz. ty
Poster #57 [10/29/11] Rating 5/5 *****
Very well writtan article and yes, I also found this "too late" to find problem. First there is a difference between AC system and DC system (easiest way to tell, DC system is rare and cheap regarding GY6 engine, and has single 4 pin CDI module which is slightly larger than AC CDI module w/ second 2 pin connector. Also, don't forget that the Stator/Flywheel housing has a magnetic nodule to pulse the Hall Effect sensor module above when it passes near. Honestly would have loved to see this article as a PDF and put on the Chinese Scooter Reference website and to promote your website...JMHO Baron Scooter (ScooterDawg website)
Poster #58 [10/31/11]
Here is what I FOUND on a 150 cc motor. No spark and it was THE 90 DEGREE CAP ON THE SPARK PLUG! There is a mechanical part with a spring and it crapped out. $2.60 part! Check your spark plug wire for continuity and if none try this fix. Hope it helps some of you out there.
Poster #59 [11/07/11] Rating 4/5 ****-
i have a twister 150 that only runs at half speed and has new carb
where do i look
Poster #60 [12/01/11]
I have a Talon GX150, the problem is the carburetor seems to not be getting any fuel. The fuel lines are clear and the engine starts with starter fluid but that is it. Is there something wrong with the choke or the carburetor that is preventing it from receiving the fuel. Any help would be appreciated. Thanks
Poster #61 [12/23/11]
Twister hammerhead has spark problem...while cranking, it fires....when you let off the key switch, it cuts off(loses spark...I assume). Two separate switches have same results. Initially, the problem was that it wouldn't even crank(starter wouldn't turn). Checked hot wire at switch after sitting(close to 12 volts). After trying to start, voltage dropped to as little as 2 volts. If I left the meter on it, the voltage would start to climb slowly back to almost 12 volts. found that my fuse holder had melted against the heat sink to one end of the fuse. After testing, found a bad fuse; however, after replacing, though the engine cranked and fired, it would not continue to fire after releasing the key. Any solutions? CDI
Poster #62 [01/09/12] Rating 5/5 *****
I have a Baja Reaction 150 that I bought very cheap because it didn't run,someone had hacked the wiring,I changed everything on it except for the harness which I could not get but thanks for your wiring diagram I was able to figure it all out and now is running perfect.the biggest problem was the green wire from CDI to ignition was not getting a ground so I had no spark.Thanks again
Poster #63 [02/04/12]
To the poster who had to hold his hand over the carb to start his 150: Check to see that you have good compression. I had to adjust the rocker arm gap on my (after buying a carb thinking the electronic choke wasn't working)intake and exhaust valves and wala it fired up and runs fine with more power! my compression was so bad (before the adjustment) that I could hold my finger in the spark plug hole and turn the engine over without it pushing my finger out at all. allanlawson@ccbcu.com
Poster #64 [02/17/12]
we charged the battery and one day it cranked it up and we put it back in an still nothin tryimg to figure out whats wrong..i need help with figuring this out? any suggestions
Poster #65 [02/18/12]
150cc gy6 "Torino". Engine starts ok when cold. will run ok for about a mile then lose power and die. Will not restart until I let it sit for about a half hour or so. 900 miles on engine. I checked the spark plug
for spark and seem to lose spark when it runs for a while. I also seem to have weak spark at the spark plug when cold. Help.
Poster #66 [04/04/12]
I have a yerf dog 150 howhit. I have replaced the cdi and rectifier but have no fire to the on off switch. Any ideas?
Poster #67 [04/06/12]
ok well i did the above and theres power to the cdi and i tested the two wires that go to the coil and theres no power. i dont no why. i bought two cdi's and neather make a diffrence. im pulling my hair out here.....
Poster #68 [05/09/12]
just bought a yerf dog and everything has been re wired i cant even get the startor to work nothing works
Poster #69 [05/19/12]
all electric parts have been chenged except the flywheel. still no spark
Poster #70 [06/09/12]
i have No spark on my Howhit 150cc. Replaced replacement CDI, coil solenoid. Still no spark. Turns over fine.
Poster #71 [06/09/12]
No spark on Howhit 15cc. Replaced CDI,and coil solenoid. Still no spark. Turns over fine.

if any one can help me please e-mail me at willbatt94@gmail.com thanks
Poster #72 [06/22/12]
My 50cc Chinese moped has no spark. Replaced coil and CDI and still no spark. While trying to remove the stator, I wrecked it. Now seeking a GY6 8 coil replacement that has TWO cloth covered winding and 5 connection wires. Can anyone tell me if a stator that has only ONE cloth covered winding will work?
Poster #73 [07/01/12]
I have no spark. Everything checks out ok BUT I do not have voltage coming out of the CDI to the coil. Stator is good,switches are good, grounds are good, signaling if good (from Stator). Already replaced CDI..maybe again....?
Poster #74 [07/16/12]
What does it mean if I have 60+ volts going to the ignition coil but still have no spark. I have tried three ignition coils including a high performance one and still have no spark. What do I try next?
Poster #75 [07/18/12]
I have a 150 urban sporty tank scooter I drop the 150 cc engine out and tried to replace it with a 50 cc engine with no luck do to mounting problems and when I replace the 150 original engine I get nothing but my starter turning over is there something I could of done knocked loose or something any help at this point would be appreciated this tank scooter has been in an electrical nightmare .my email address is j.a.e.kchumpychef@gmail.com
Poster #76 [08/12/12]
New spark plug, new coil, new cdi, and new stator. Still no fire! Bypassed kill switch, and tested all the wiring. Wth? It's a Twister hammerhead GY6 150cc.
Poster #77 [09/07/12] Rating 5/5 *****
I can't believe that this problem can't be solved by one aha! There's a lot of good mechanics including me on this thread and I think a lot of us on this thread have the same exact problem. Mysterious, makes no sense, Intermittent spark. I've gotten mine to run several times but don't know why. Every once in a while the cdi to coil circuit comes up to voltage and it starts right up when I reconnect all the wires. Sometimes runs fine for a few minutes to a couple of days. Itís run a couple of days twice but canít trust it so I donít go far. Eventually I loose spark again-- the same problem most of you are having. No spark. I know I'm getting gas cause the spark plug gets wet. Dry the plug no spark, no start, and plug get wet again. I'm thinking it's the hall effect sensor but can't prove it yet.

By the way concerning the buggy autochoke problems. I never start any autochoke scooter goosing the throttle. Assuming the throttle is set to idle good when it does start, I just push the button for a second or too even in the cold and after a 2 or three two second tries with no goosing of the throttle donít touch it at all---the motor comes to life and in about thirty seconds you can try a little goose. If it dies try again no goosing and let it warm up another 30 seconds. It's warm enough when goosing revs the engine and doesn't kill it. After that it starts normal i.e. a tiny bit of throttle and push start button, tho sometimes no goose or full throttle to clear out a flood condition is necessary. Keep you turn overs unded three seconds. If it wonít start in three seconds it wonít start in 5 seconds and you risk the starter motor. You have to know your particular engine. Usually after the morningingís no goose start up routine unless itís winter and has sat a few hours. In that case do the no goose routine. Works every time for me on several different scooters. If you goose it before it starts you'll easily flood it so resist.


Other problems described here. Don't over look the fuse. Make sure good sturdy american fuse, right amperage and good connection to fuse terminals in bullet case. Make sure good ground. Over do it if you have to.

Further thoughts on mysterious no spark problem

I second the ground checking idea. I'm going to put in a separate ground wire even two to try to get my spark back. Spark is everything I don't think it's the coil, I don't thinks it the cdi, or stator. I know this cause i've put on the originals and it's worked for a day or two and I've mixed new with old ignition parts and that works too. Even my old junky cracked insulation spark plug coil wire coil still works when the voltages start behaving. Were missing something that I think is endemic to these gy6 engines. If one person solves it well all be fixed. It's junky chinese wires or a buggy hall effect spark sensor system-- I think but canít proove it yet-. Iíll be back and write the solution here when I figure it out. God willing I will figure it out. He loves persistence.
Poster #78 [09/07/12]
I found this no spark fixit idea and am excited to try it. I wondered about the connector but it seemed and looked fine. I'm going to focus on that next.

other site no spark thread responders idea:
FINALLY found the problem! Pretty sure. It was a bad connection. The 4 plug connector (ground, black/yellow wire to coil, & trigger wire), and the 2 plug connector (kill & stator wire) were not making good contact where it plugs into the CDI. This would explain why I was getting no voltage coming out of the CDI or at the coil and also why it would only run sometimes.

The connectors were wore out bad, so bad that I could wiggle the wires while someone tried to start it and it still wouldnt start! I would go to say 2 or 3 of them werent making contact. I stuffed some strands of 18 gauge wire in each connector end (as a quick test) and it fired right up. Drove it for a good while and everythings fine.

What a relief! I hope this helps someone who has similar problems. I always hate it when someone doesnt come back and post how they fixed the problem.

Man, I know this ignition system front and back now!

Thanks for the tip on scooter parts being interchangeable.
Poster #79 [09/13/12]
I have been having the same problems. I have a Carter Talon that has a hydraulic brake that has a hydraulic switch apparently it malfunctioned and everything worked fine after bypassing it. something for you to try before tearing the whole thing apart. steve from texas
Poster #80 [09/19/12]
I have a Hammerhead Twister, single seater and it was a pain to start. Changed Spark plug, new battery as the old one was really stuffed, new carb, new Coil and CDI. Still a pain to start BUT after reading this article I have fixed it. I started to setup the test process, I noticed after putting a second ground wire on the CDI , No.4, I got my spark back. Nice and strong like never before. So I made this permanent and now its starts like new for the first time since I bought it 2nd hand. Now I cannot shut the engine off because the person before me stuffed up the 'Engine Stop' button. I will be putting in a new one tonight and hopefully ready for the weekend. Thanks again for the article and all your comments it helped me a lot. Why are these buggies so problematic, are the later models better built? Thanks again
Poster #81 [09/19/12]
I have a Hammerhead Twister, single seater and it was a pain to start. Changed Spark plug, new battery as the old one was really stuffed, new carb, new Coil and CDI. Still a pain to start BUT after reading this article I have fixed it. I started to setup the test process, I noticed after putting a second ground wire on the CDI , No.4, I got my spark back. Nice and strong like never before. So I made this permanent and now its starts like new for the first time since I bought it 2nd hand. Now I cannot shut the engine off because the person before me stuffed up the 'Engine Stop' button. I will be putting in a new one tonight and hopefully ready for the weekend. Thanks again for the article and all your comments it helped me a lot. Why are these buggies so problematic, are the later models better built? Thanks again
Poster #82 [09/20/12]
Does anyone know what colour wires go to what terminals on these older style ignition switches please, 3-screw, keyswitch 6.000.158-1. Thanks again
Poster #83 [09/24/12]
I now have a running 150cc Hammerhead Twister but ever since I put a new earth to Pin 4 on CDI and a new Kill switch - two connectors, I get a battery drain over 2 days. I am going to put in a battery isolator but would like to know what is killing my battery now. Any ideas anyone.??
Poster #84 [09/29/12]
2005 gx150r2 I replaced the.coil,cdi,new motor,starter relay,and main fuse . But now my problem is it wont turn over with the key. But will start if I jump the starter relay solenoid? What needs to bee replaced, so I can start with key.
Poster #85 [10/02/12]
Imy 150 wouldent start so i put some jumping cables on da baterie from my truk after a while the red and the black wires started to smoke up and it wont turn on
Poster #86 [10/12/12]
I bought a used 2007 Sun L Adventure scooter with a GY6 150cc engine with 350 miles.It ran fine for 6 weeks and now no spark.After reading all the posts on all of the replaced parts and still no results,im thinking im not going to waste my time or money on it and just disect it for the learning expereience and throw it away.Its a shame this problem cant be fixed.Good luck with yours.
Poster #87 [11/29/12]
try checking resistance across black/red wire on the stator.i had same problem with no spark.i got false reading on ac voltage(11 vac).come to find out i had a broke wire on stator when engine fell off table during assembly.changed stator and got spark back.
Poster #88 [12/03/12] Rating 4/5 ****-
i bought a used tomberlin crossfire 150 gy6 im getting no spark i change complete ignition system the coyl and pick up skater spark plug and regulator but still getting no spark the engine spins well and has compression but do not know y please help thx.
Poster #89 [01/27/13]
Check green wirr going to stator run new wire from therr to batt. Negitive.
Poster #90 [03/15/13]
this helped me fix my problem thank you
Poster #91 [04/01/13]
I am having problems with mine I rode it for the day sat it for a couple hours went back on and would not start. there is power but seems like the starter button is not working. nothing sparks what do I do?
Poster #92 [04/18/13] Rating 5/5 *****
I had all of the above spark issues. Replaced everything including the ignition switch, Stator, coil, CDI, spark plug. Same problems persisted. Finally I put the old CDI back in and it runs great. They obviously have ignition switch defects and CDI defects from their manufacturer.
Poster #93 [04/26/13]
I have a crossfire 150 it runs at idle but thats it, if you press on the gas it dies, carb and fuel is fine, any thoughts?
Poster #94 [05/22/13]
What is the flywheel to pick up module gap (For the CDI trigger for the 150cc)
Poster #95 [05/26/13]
yerf dog 150 cc wont turn over from the key swith. It will turn over by jumpering the starter solenoid. what should i check?
Poster #96 [06/06/13]
I have a 150cc that I replaced a complete motor but after asssembling It wont run, it has turnover but wont start, I did a spark test and there is no spark, the problem that i have is that my old motors wires are not the same color as the new motor, can anyone assist. my new motor has 3 orange wires a blue and a green. my existing wires on the scooter are white yellow green red/black white/red.....please help!!!!!!!
Poster #97 [06/21/13]
My gocart sparks sometimes if i rapidly switch off the key and turn it back on and try to start it, it sparks sometimes... please help me im getting real desperate and it has a new engine in it..i've checked all connections could there be like a bad wire or something?? please help
Poster #98 [07/06/13]
What colors r the #4 and #5 wires on the cdi box?
Poster #99 [07/14/13]
how do I tell the difference between an ac/dc cdiyes
Poster #100 [07/25/13] Rating 5/5 *****
I want to thank you for this step by step process. I was racking my brains for days until I found this page. I have a crossfire 150r and I couldn't get it to spark. I had to take the #4 to ground and cut #5 wire, started right up. Thanks again, this was great help.
Poster #101 [08/01/13]
Reply for poster #97.... I just had to do the same switchover. Your new stator assembly has twelve poles, and your old one has six. The green white and yellow wire will be replaced with the three orange wires, and you will likely have to switch your plug end as well. Each of those three wires corresponds with one of three poles on the stator. (a left, middle, and right) You will need to remove your old plug from the old stator, and match the three wires to the corresponding poles and orange wires on the new stator. Your old black and red wire is now the green wire (you may have to modify the connector) and your red and white wire is now the blue wire. ....or you can just buy a new six pole stator assembly.
Poster #102 [08/01/13]
Reply for poster #97.... I just had to do the same switchover. Your new stator assembly has twelve poles, and your old one has six. The green white and yellow wire will be replaced with the three orange wires, and you will likely have to switch your plug end as well. Each of those three wires corresponds with one of three poles on the stator. (a left, middle, and right) You will need to remove your old plug from the old stator, and match the three wires to the corresponding poles and orange wires on the new stator. Your old black and red wire is now the green wire (you may have to modify the connector) and your red and white wire is now the blue wire. ....or you can just buy a new six pole stator assembly.
Poster #103 [08/29/13]
sure wish I would of read this before I got into this mess
Poster #104 [09/10/13]
I have a 08 250cc scooter when I try to crank my lights cut off when I press the brake anyone had this problem I replaced the cdi box, ignition coil spark plug still want do anything my starter wire gets hot and tried to melt. Do I need a stair coil I haven't changed that yet. Thanks
Poster #105 [10/10/13]
Just bought a Yerf-Dog Go-Kart #42101 and is missing the the wiring cover. I noticed the wires starting to get hot when I connected the batery. There are three yellow wire with bare ends tied together. Anyone know what these three wires go to. I bought a new rectifier and I am about to try it again.
Poster #106 [10/10/13]
just bought a Yerf-Dog Go-Kart #42101.
I also notice the black from the battery is attached to the screw holding the rectifier. Is that correct?
Poster #107 [11/07/13]
I got my 7year old a used 49cc OFLY and ign coil went bad . I have a new gy6 ign coil layin around . WILL IT WORK ?
Help .... by the way your web sight is GREAT
Poster #108 [11/07/13]
I got my 7year old a used 49cc OFLY and ign coil went bad . I have a new gy6 ign coil layin around . WILL IT WORK ?
Help .... by the way your web sight is GREAT
Poster #109 [12/01/13]
My foxfire 150 gets one spark when u turn the key and won't fire after that anybody have an idea why it fires one time and that's it. I can turn the key off and give it a few minutes and it will fire one time and I'm lost please help.
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