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Discussion Starter #1
Hello , I am attempting to fix up my friends dad's quad . He just had surgery for prostate cancer and owns a rural property with quite the driveway here in Canada , so he needs the quad to be able to plow snow .

Recently I had done the differential swap from an old mid 80's fourtrax 250

But now I'm working on the starting issues . He doesn't have the strength to kick start it like he used to , and now is depending on the starter button that never worked unless hot and after depressing.

So I checked compression it has 160 psi dry and while plug was out checked for spark but noticed that it only sparked after the starter was depressed and still spinning.

I ended up trying a late 80s trx350 CDI box but that didn't get any spark .

So I plugged the old CDI box back it and now it has consistent spark but it is really weak . A faint blue .

I put it on a car charger to try with 15 amp for a few seconds and the spark didn't get brighter.

So I put the plug back in and tried but no luck even with starting fluid and new plug. Not even a cough . Plug still consistent but weak .

I have searched countless sites only finding that it might be a recall part that was only an issue on 95-96 trx300

the battery has always been charging when running able to operate a winch for the blade and headlight no problem.

if anyone could shine some light im going to continuing on it tomorrow and try to test for voltages .

if it helps the quad was found in a muskeg swamp abandoned is where it came from . Has always had this issue

I appreciate any help
excuse my grammar
 

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Here's the ignition system - weak spark is generally poor connections (especially grounds), spark plug cap, coil, CDI box or battery


4470


I don't know about a recall, but the CDI unit (part number 30410-HM5-672 superseded to 30410-HM5-505) was the same for the following models:

1994 TRX300 A - WIRE HARNESS
1994 TRX300 AN - WIRE HARNESS
1994 TRX300FW A - WIRE HARNESS
1994 TRX300FW AN - WIRE HARNESS
1995 TRX300 A - WIRE HARNESS
1995 TRX300 AN - WIRE HARNESS
1995 TRX300FW A - WIRE HARNESS
1995 TRX300FW AN - WIRE HARNESS
1996 TRX300 A - WIRE HARNESS
1996 TRX300 AN - WIRE HARNESS
1996 TRX300FW A - WIRE HARNESS
1996 TRX300FW AN - WIRE HARNESS
1997 TRX300 A - WIRE HARNESS
1997 TRX300 AN - WIRE HARNESS
1997 TRX300FW A - WIRE HARNESS
1997 TRX300FW AN - WIRE HARNESS
1994 TRX300 A - WIRE HARNESS
1994 TRX300 AN - WIRE HARNESS
1994 TRX300FW A - WIRE HARNESS
1994 TRX300FW AN - WIRE HARNESS
1995 TRX300 A - WIRE HARNESS
1995 TRX300 AN - WIRE HARNESS
1995 TRX300FW A - WIRE HARNESS
1995 TRX300FW AN - WIRE HARNESS
1996 TRX300 A - WIRE HARNESS
1996 TRX300 AN - WIRE HARNESS
1996 TRX300FW A - WIRE HARNESS
1996 TRX300FW AN - WIRE HARNESS
1997 TRX300 A - WIRE HARNESS
1997 TRX300 AN - WIRE HARNESS
1997 TRX300FW A - WIRE HARNESS
1997 TRX300FW AN - WIRE HARNESS
 

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Discussion Starter #3
Here's the ignition system - weak spark is generally poor connections (especially grounds), spark plug cap, coil, CDI box or battery


View attachment 4470

I don't know about a recall, but the CDI unit (part number 30410-HM5-672 superseded to 30410-HM5-505) was the same for the following models:

1994 TRX300 A - WIRE HARNESS
1994 TRX300 AN - WIRE HARNESS
1994 TRX300FW A - WIRE HARNESS
1994 TRX300FW AN - WIRE HARNESS
1995 TRX300 A - WIRE HARNESS
1995 TRX300 AN - WIRE HARNESS
1995 TRX300FW A - WIRE HARNESS
1995 TRX300FW AN - WIRE HARNESS
1996 TRX300 A - WIRE HARNESS
1996 TRX300 AN - WIRE HARNESS
1996 TRX300FW A - WIRE HARNESS
1996 TRX300FW AN - WIRE HARNESS
1997 TRX300 A - WIRE HARNESS
1997 TRX300 AN - WIRE HARNESS
1997 TRX300FW A - WIRE HARNESS
1997 TRX300FW AN - WIRE HARNESS
1994 TRX300 A - WIRE HARNESS
1994 TRX300 AN - WIRE HARNESS
1994 TRX300FW A - WIRE HARNESS
1994 TRX300FW AN - WIRE HARNESS
1995 TRX300 A - WIRE HARNESS
1995 TRX300 AN - WIRE HARNESS
1995 TRX300FW A - WIRE HARNESS
1995 TRX300FW AN - WIRE HARNESS
1996 TRX300 A - WIRE HARNESS
1996 TRX300 AN - WIRE HARNESS
1996 TRX300FW A - WIRE HARNESS
1996 TRX300FW AN - WIRE HARNESS
1997 TRX300 A - WIRE HARNESS
1997 TRX300 AN - WIRE HARNESS
1997 TRX300FW A - WIRE HARNESS
1997 TRX300FW AN - WIRE HARNESS
Thank you for your help . It was the coil ground terminal corroded. As well as both spades on coil . I imagine from being sunk

Bless you
 
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