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Discussion Starter · #1 ·
I have a 1999 AC 500 4x4.

- New Battery
- New Ignition Coil
- New Fuses and fuse box

But no Spark.

I have put my volt meter on the "White/Blue" wire going to the Ignition Coil (As recommended in the Manual) and with the key in the on position I get the allowed ~31 volts. But when I push the start button it drops to ~27 volts instead of going up to ~130 volts like it should.

Can anyone help me figure out where my issue it? Magneto? CDI? Something else?

Thanks in advance,
 

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Discussion Starter · #2 ·
Next, I have put on a new CDI and still no spark.

The only change is that now when I run the voltage test on the "White/Blue" wire going to the Ignition Coil I get ~31 volts sitting still and ~31 volts when the starter is engaged.

Any ideas. I am grasping a straws here. I dunnoI dunnoI dunno
 

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Have you tested the voltage regulator/rectifier?
 

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Discussion Starter · #6 ·
Got a Manual, Ran the voltage tests and the B/R, B/W reading all seemed to be backwards and just a bit off.

So with that, I scoured the internet and found a new one for about $60. Figured it was worth a try.

When it comes in I will test it our and let you know if it works.

Is there anything else I should be checking while waiting for the UPS guy?

Thanks,
 

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I just went thriugh that with my 2007 500.

Start by checking all the wiring continuity that interacts with the ignition and the magneto. You can follow most of it back to the connector plug at the CDI. Pay particular attention to wiring in the steering as it gets worked back and forth and can fracture inside the insulation
I found a bad connector plug for one of the wires for the magneto trigger.

Check your kill switch for continuity.

The voltage will read negative at the coil when cranking with the starter.

If that all checks out OK you will need to pull the left side cover and make sure the magnets are still on the rotor (flywheel)
 

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Discussion Starter · #8 ·
Well, one step forward and two steps back.

I got the magneto fixed, or more so repositioned and now I am geting a good spark.

New Problem is that the engine is pushing air in the wrong direction. I sprayed some starting fluid in the intake side of the carb and it spit it back out at me. Just to conferm I put my hand on the exhaust pipe and I was sucking in instead of pushing out.

I am going to assume that means my timeing is off and I am on the wrong cycle of the piston. My question is, who do i fix it?

Thanks,
 

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Discussion Starter · #9 ·
Setting timing.

Does this sound right to get the timing set correctly?

A. Piston at Top-dead-center
B. Camshaft lobes directed down (Toward the piston)
C. Camshaft alignment marks parallel to the valve cover mating surface
D. Recessed side of the sprocket directed toward the cam lobes
E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned
 
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