85 250R very little spark

[jason0779]

Was wondering if anyone had any ideas. Just completely rebuilt a "field find" atc 250r and i'm having problems with very little to no spark. Checked the AC regulator, the CDI and the coil, they all seem fine. Very frustrating considering I was going to try and start her up tomorrow for the first time. Any help would be great. If i hold the spark plug I feel very little spark.

Thanks,
Jason

[250rRoostmaster]

Have you checked your ground wire? Make sure it's squeeky clean where it connects to the frame! Also check the plug wire

[jason0779]

Yeah i check that. Also tested everything with a Ohm meter. Do you think possibly the alternator is bad?

[jason0779]

I mean i'm pretty new to 2 strokes, but everything I've owned before you got a hell of a jolt when it shocked you. You know hold the plug/sticking a screw driver in the spark plug cap. This thing I can hold with my hand while i'm kicking it and it just barely tickels my finger. Sometimes not at all.

[250rRoostmaster]

The CDI is probably shot, ive had to replace mine of a couple different machines with weak to no spark...

[jason0779]

141798141799141797

I think I might have found the problem. Popped the alternator cover off to discover that mess. I posted a pic of what I started with and a picture I took the other day after mounting the gas tank.

[RoscoW]

Holy cow that is one nasty crusted up flywheel. I'd be surprised if that wasn't your problem.

Ross..

[Kenny_smallz]

I wonder what the rest of the engine looks like on the inside?

[250rRoostmaster]

Uhh yea thats definatly a problem!! lol I'm suprised you get any spark at all with that thing looking like that!!!

[jason0779]

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Kenny Smallz,

That is what the rest of the motor looks like on the inside. I had already redone the top end and everything looked fine. Cylinder looked great. I had a crack around one of the bolts where the right crank case goes so I had already had it off and had the crack fixed. Just didn't really think I had a reason to pull the left side off.

[jason0779]

Haha yeah no kidding. Like I was saying to someone else I just didnt think I had a reason to pull that cover off. I told myself "all that is in there is the alternator/stator/pulse generator right" and everything was testing good with a Ohms meter(Well I was WRONG). I have a new left crank cover, gasket, new flywheel/stator/pulse generator, and puller all on the way. It might have worked after cleaning it out but I figured I've done this much might as well get that crusted up flywheel out of there. Turns out there was no gasket there. Thats probably why the damn thing quit running 10 years ago and was sitting ever since.