Hi everyone, I've just bought a 99 wr 360. I bought it with a starting issue, it has an intermittent spark fault ( more often than not it won't spark and when it does it will only run for a second or so ) the old owner has replaced the coil, CID unit and had the stator re-wound but the regulator/ rectifier has not been changed. Could this be the problem? I've been through the wiring diagram and it all looks good only thing is it shows an earth wire going to the body of the regulator/rectifier and there isn't one on the bike. I've cut the wire to the kill switch just in cease that was the fault but I'm at a loss as to what it could be. Any help would be greatly appreciated Thanks
1st, i'd take the front motor mount plates off & clean them, wire brush them, where they contact the frame. I'd clean up the frame area too, I'd also take the coil off & clean the mounting areas there too. You can run an extra wire from one of those lower motor mount bolts up to the coil mounting area as well. If that didn't fix it, I'd unwrap the wiring harness & look at all the wires very carefully. Take you time & don't leave any wires unturned, pull all the connection apart & use contact cleaner on them all. Good luck Husky John
hi ash, reg/rectifier only controls lights etc and not the cdi, basically your stator will have 2 windings one for ignition and one for the lights etc you will need to check all connections etc do you know for sure that the parts have been replaced?, have a look and let us know what you see, cdis rarely fail same for coils but stators get hot and the insulation on the winding breaks down, you may have to get some ohm readings and check them against the workshop manual specs or use this forum search.the reg is earthed through the body basically excess voltage is earthed to the the frame through the bolts holding the reg.my 360 never had a strong spark but also had the decomp valve and was easy to kick over.
on all trouble shooting but especially electrical go back to basics for sure, don't guess a new spark plug is ok, don't guess anything done before is ok replace the plug with a tested unit (do you have another bike), check the kill switch, check the connectors, then start the diagnosis of the hard parts, my 99 had a bad stator, but it was a hot starting (well always hard but really hard hot) problem, that year they used a Kokusan ignition mine is not very impressive new, my KTM 380 would start when you were cycling the engine at a slow rate this one you get it on a stand and get it spinning fast I wish you the best on your gremlin hunt, keep us informed
Been racking my brain and trying everything but nothing seems to work so ive taken it to a shop. I will post the outcome as soon as I get it
Got it back, it was a dodgy coil lead and plug cap. I'm such an amateur. Thanks for everyone's help.will post pics whenits ready
