2001 Warrior with Weak Spark

[Yamahonda41]

Hi all,

I have 2001 Yamaha Warrior that will run when bumped or jumped with hi amperage boost.  I replaced the pickup coil in the stator assembly 2 years ago and again 2 weeks ago.  I thought it was the same problem. 

I checked the resistance on the primary and secondary of the ignition coil and it was a little out of spec so I bought a new one.  No improvement.  I compare my Warrior's spark to that of a Raptor 350 with same engine and there is a DEFINITE difference.  The raptor is bright in comparison.  I tried the spark plug cap from the Raptor.  No difference.

Local dealer told me the CDI pack doesn't usually get "weak" rather it either works or doesn't.

Any ideas on what to check next? 

Thanks,

Dave/Yamahonda41

[KB]

 Does the pick-up coil needs to be properly gapped where it comes in contact w/ flywheel ? Banhee's do.

[Mrs.Nightbreed]

No spark would be stator, coil or CDI. The only time I have seen weak spark is if a coil wire is frayed somewhere or the stator, which you've already replaced. Although, on one occasion I have seen a brand new, out of the box stator, be bad.

Aside from the weak spark, what happens when you actually run it? CDI's do crazy things when they go out.

[Yamahonda41]

KB - I don't know that answer.  I remember the pickup mounting holes had not adjustment that I could see.  Would make sense if it is too far away the mag field would be weaker and generate less spark.  I guess I can pull it apart again and check it.  Thanks,

Ms. Nightbreed - It seems to run fine.  I just had the valves replaced because it had lost some compression and was smoking after startup.  Now no smoke, compression is good.  I hate these kinds of problems!!!

I also need to check the wiring harness and all the connections.  This quad has seen it's share of mud and water.

[k.p.]

in my experience warriors crap out alot. it really sucks when you know where the problem is coming from but you dont know how to fix it. its very frustrating.well i wish you luck.

[Yamahonda41]

According to RMStator I need a new one, not just the pickup coil.  Cant be anything else it is all new!!! 

[Yamahonda41]

Crap!  Put new stator in and now instead of weak spark I have NO spark   

[gery350]

i believe your gonna hve to pull out the manual and the dvom and start checking for signal, voltage and resistance.
good luck,
gery

[lugnuts]

wow I just went through this with a warrior I had here to repair (weak spark) I found out that the factory yamaha stators had alot of problems with this and the dovetail would come loose and fall into the flywheeel/rotor and cause this problem I replaced the stator with a new ricky stator that has a improved "dovetail" and also replaced the cdi and regulator/rectifire problem solved. I also have a 99 warrior here that im parting out if you want give me a call its still mostly there I can give you some readings from this one with a dvom of if you are close to pinellas county and want to try some parts let me know if I can help
727-432-0270
steve

[lugnuts]

also unplug the handel bar switch I have seen them short to ground ie:wire rubbed and touching the frame or switch full of dirt do the same thing