BASIC TROUBLE SHOOTING
Ignitions operate on simple principles.
Low battery voltage is converted to high voltage using a coil or set of coils.
The coil must be turned "on or off" at the proper time to operate the engine.
Ignitions need two things to function:
The module must have proper power supply and ground to operate.
The coil(s) must have proper power supply, ground, and trigger signal from the module.
Over voltage (spikes) are the #1 cause of failure!
If your vehicle stops running, you must determine if the issue is electrical or fuel.
We get calls about issues regarding no spark or intermittent spark. In 99% of the cases, we end up finding a problem on the vehicle side of things. If you are not an expert with electricity, please have someone help you so that parts are not damaged.
Low battery voltage is converted to high voltage using a coil or set of coils.
The coil must be turned "on or off" at the proper time to operate the engine.
Ignitions need two things to function:
The module must have proper power supply and ground to operate.
The coil(s) must have proper power supply, ground, and trigger signal from the module.
Over voltage (spikes) are the #1 cause of failure!
If your vehicle stops running, you must determine if the issue is electrical or fuel.
- Ground the sparkplugs on the engine and rapidly crank the engine. Observe if spark is present at the ground strap of the plug. NEVER attempt to crank the engine without the spark plugs properly grounded. It can easily damage the coils.
- If you don't have spark, replace them and check for secure fitment of plug caps.
- Verify battery voltage is at least 10 volts while cranking the engine. If you have a small amp capacity battery that still might not be enough to start it. Carefully use a small jumper pack or similar size battery to help start it. NEVER use a plug in booster device or battery charger with the key turned on. You can easily destroy electronics!
We get calls about issues regarding no spark or intermittent spark. In 99% of the cases, we end up finding a problem on the vehicle side of things. If you are not an expert with electricity, please have someone help you so that parts are not damaged.
** A WORD ABOUT ROUTING WIRES**
Avoid routing or securing any ignition or coil wiring to the alternator output wires or spark plug wires! This can allow dangerous high voltage EMI spikes to affect timing and damage or failure could occur.
Wrap the ignition wires in a manner that avoids cross feed. If you are using a handlebar emergency switch or a pulling tractor with safety kill switch use a quality device that locks in place. Avoid using cheap or loose connections that can cause electronic failures.
Wrap the ignition wires in a manner that avoids cross feed. If you are using a handlebar emergency switch or a pulling tractor with safety kill switch use a quality device that locks in place. Avoid using cheap or loose connections that can cause electronic failures.
Proper Spark Plug (High Voltage)
Coil Construction
When shortening or making a set of spark plug wires, there are certain things that need to be done correctly. You also need the proper tool if you are crimping on terminals.
Here is a photo gallery showing the proper method. If you aren't sure what to do, please bring to a certified repair facility to avoid issues. Burned or over heated components are not covered by warranty and are preventable!
Here is a photo gallery showing the proper method. If you aren't sure what to do, please bring to a certified repair facility to avoid issues. Burned or over heated components are not covered by warranty and are preventable!
Use silicone to lubricate the boots when installing them. It helps the cable slide and prevents damage. Some terminals require the boot to slide over the wire BEFORE the terminal is crimped in place.
The wires on the left were improperly crimped and the internal wire had not been stripped back and folded over. The result was the wires burned as the coil tried to jump the gap. The coils eventually over heated and melted. The wires on the right were correctly stripped back and crimped (factory Moroso crimp shown). This is the correct method.
The wires on the left were improperly crimped and the internal wire had not been stripped back and folded over. The result was the wires burned as the coil tried to jump the gap. The coils eventually over heated and melted. The wires on the right were correctly stripped back and crimped (factory Moroso crimp shown). This is the correct method.
VOLTAGE FAILURES
Signs of heat related failures are a direct result of voltage spikes or "over voltage"
TUNING GUIDE
Fuel mixture, ignition timing, fuel burn rate, load, and the number of spark events are all related. If any of these items are changed, it affects engine operation.
- Fuel Mixture - Air–fuel ratio (AFR) is the mass ratio of air to fuel present in a combustion process. The AFR is an important measure for efficiency and performance-tuning.
By Clamothe - Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=16193129
We have found a Lambda mixture of .85 is a great starting point. Most tractors that we have measured are too lean.
You can't fix what you don't measure. We found every tractor that pops was very lean at that particular rpm. Once we adjusted the carb to the correct AF ratio, the popping went away. On some engines we also discovered fuel delivery issues (restrictions in the venting, fuel supply, filters, or needle/seat size).
Once we opened up the fuel system to allow the carb to be correctly adjusted, the noise went away and we found performance had increased.
You can't fix what you don't measure. We found every tractor that pops was very lean at that particular rpm. Once we adjusted the carb to the correct AF ratio, the popping went away. On some engines we also discovered fuel delivery issues (restrictions in the venting, fuel supply, filters, or needle/seat size).
Once we opened up the fuel system to allow the carb to be correctly adjusted, the noise went away and we found performance had increased.