90' js440 igniter question
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  1. #1
    PWCToday Newbie
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    90' js440 igniter question

    Hey there, my wife has turned over our js440 project to me since we have a no spark issue. I know people were saying the the stop button can malfunction on these but I do not believe this is the issue. I took apart the electrical box to check for corrosion when I noticed the connector cord that ties into the igniter CDI had some problems. One of the connections looks like it sparked and I'm wondering if the igniter is bad. Here are some pictures...





    My questions are...
    Is there anyway to but a multimeter on this and check the igniter?
    Are the pictures evidence enough to determine its the problem?
    Where to find new parts?

    Thanks all!

  2. #2
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: 90' js440 igniter question

    Always test spark with both plugs grounded at the same time

    Is the ground wire fried?

    There are 2 basic tests.

    1). Swap out the coil with a known good coil. If no spark, look at grounds,
    and then the stator.

    2). An AC voltage test on the stator. If either of the stator coils fail, you
    found the problem.

    Test for ACV between the exciter and pulser coils and ground while cranking
    the engine over.

    CAUTION
    : Crank the engine over with spark plugs in the head, and plug
    wires grounded to the head nuts to prevent the engine from firing.

    Test vac at the 5 wire connector from the stator while it is still connected to
    the ebox. Reconnect the ground jumper wire from the engine to the ebox.

    (1) (exciter coil) Red wire from stator & Black wire from the stator. Greater than
    60 vac

    (2) (Pulser coil) Gray wire from stator & Black wire from the stator. 30 to 35vac

    The only other tests are to check the spark plug wire continuity, check for broken
    high tension wires. check the spark plug cap connection, and to disconnect the
    black and white wire from the stop switch relay, or the terminal inside the ebox.



    Bill M.
    Horsepower == Speed, RPM != Speed



  3. #3
    PWCToday Newbie
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    Re: 90' js440 igniter question

    Hey thanks for the response, that's exactly what I needed to know! I haven't been able to test yet but I have some extra info, the wire that has the damage in the plug is one of the green wires that actually runs between the magneto and regulator. Because the engine cranks I'm guessing that this is not the problem but I can run a quick resistance test. My gut tells me coil based on how it died by stopping while someone was riding and then not being able to start again but I will explore the relay as well.

  4. #4
    PWCToday.com Is My Home Away From Home wmazz's Avatar
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    Re: 90' js440 igniter question

    I never seen a problem with a stator wire, but when the voltage
    regulator dies it usually fries the ground wire and some times the
    charging coil.

    Your ignition coil looks good. In many cases the ignition coils iron
    core is rusted on bad coils.

    You can also test the copper hi-tension wires by cutting them back
    the insulation to expose the wire. Then use a good pliers, needle nose,
    or side cutters to pull on the copper wire. If any wire pulls out, you
    have a bad coil.


    Bill M.

    I included a good example for testing spark, and because you may be
    pulling the flywheel, I have instructions available for that.

    If you don't properly torque the flywheel, it will cause damage to the
    crank and flywheel tapers.
    Attached Files Attached Files
    Last edited by wmazz; 05-26-2019 at 02:46 AM.
    Horsepower == Speed, RPM != Speed



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