1988 Wave Runner WR500 No Spark! - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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Old 06-08-2010, 02:42 AM   #1 (permalink)
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Default 1988 Wave Runner WR500 No Spark!

Hello. I just recently purchased a 1988 Wave Runner with the WR500 motor in it. The problem I'm having with it is I'm not getting any spark. The guy i bought it off of had taken it apart and bought a used CDI module, coil, and started solenoid. But he gave up working on it, so i bought it off him.

So heres where I'm at. I have replaced the Stator with one off eBay. The CDI box that came original on it was the 6K8-10 and the one that came off eBay is a 6K8-11 Other then the White/Red Stripe wire connector being wrong. the two modules look to be the same and from what iv read should work. With a test Light iv determined that I'm getting current from the Brown wire off the stator which runs into the CDI module. So assuming that the stator is functioning ok, Iv disconnected the Safety Switch at the handle bars.

I unhooked the Orange Wire going from the CDI to Coil and with my test light, checked to see if i was getting current while turning over the motor.. The test light did not light up. Iv tested this with Both CDI Modules, and got the same results? Now I'm suspecting that i have two bad CDI units here. Could this be possible? Or did i do something wrong in my testing to make me think this? Is there a test procedure that i can do in order to check my CDI Unit?

Iv ordered the Clymer Manual, but I'm not sure how long its going to take to arrive, as i wasn't able to get one locally. If any one has a wiring schematic for this Wave runner and could possibly E-mail me a PDF of it that would be very help full.

Thank you.
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Old 06-09-2010, 09:53 PM   #2 (permalink)
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Alright well problem solved.. Bot my CDI modules were bad. So i bought a new one that i knew worked 100% and its sparking now.
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Old 05-13-2012, 12:07 PM   #3 (permalink)
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do you still have the ski, im having the same problem and have not been able to come up with answers, could u tell me what voltage u r getting out of the stator, and what voltage goes to coil, so i can determine if its a bad stator, cdi, or coil
thanks
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Old 05-14-2012, 01:41 PM   #4 (permalink)
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Hey I have 2 of these so I think I can help. I had to replace the CDI on one of them and the other had an intermittent kill switch that kept it from firing. I replaced the kill switches with 2 aftermarket units from Pro Design and they work great.

One easy way to isolate the switch is to unplug the black and white wire harness near the hinge cover in the engine compartment. If you get spark, the switch has an intermittent short and will usually work if you wiggle it, but you will never fix it permanently. The little spring in there gets weak and doesn't push up quite hard enough to remove the short in the kill circuit.

FYI, On my ski with the bad CDI I got about 8-10vac at the input of the coil. The good ski got about 40-48vac.
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Old 05-14-2012, 10:09 PM   #5 (permalink)
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i did check the switch, i have 0 volts at coil, do u happen to know output voltage from stator, it seems we are a rare breed to enjoy these old slow ugly skis but i like them, i had an 87 wave jammer and wish it didnt die, if not i do appreciate the info provided
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Old 05-15-2012, 08:06 AM   #6 (permalink)
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Here the electrical specs from the service manual
Attached Thumbnails
1988 Wave Runner WR500 No Spark!-electrical.jpg  

Last edited by carhopper; 05-15-2012 at 08:10 AM.
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Old 12-31-2012, 01:57 AM   #7 (permalink)
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You can modify these easily and cheaply folks, as an ex electronics guy i have found the fix, the problem with most 500, 650 and some others is that the CDI box has a rev limiter, you can order a CDI through jaycar electronics $50 AUD, or you can order a high performance CDI off ebay.

The CDI off jaycar works like a dream, beware though the main diode coming off the charge coil may blow so replace with a 40volt 3 amp schotsky diode parallel with the 5804 diode.

Be warned though, this thing now flies but you need to limit the revs otherwise your head will blow.

P.S, if anyone has a problem with the coil you can buy a second hand coil for the new cars, these coils are one but have outputs for two spark leads and should read about 3-5 ohms, connect to the ground and orange wire off the CDI, it does not matter which way on these, the older ignition coils have a ground and positive, the park plug gap is 0.24"-0.31".

Last edited by viper000; 12-31-2012 at 01:59 AM. Reason: plug gap ammended
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Old 01-18-2013, 11:47 PM   #8 (permalink)
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sorry folks, needed another 0, it is 0.020"-.024", or 0.5-0.6mm for the spark plug gap, also, the jacar unit died, so purchased a CDI off ebay for $12, these are for the ATV, i also have the whole wr500 & wj650 service manual in PDF form.

I don't get on here much but will look from time to time if anyone needs to know anything.
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Old 01-24-2013, 05:31 PM   #9 (permalink)
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here is the CDI i purchased off Ebay at this site

High Performance Racing CDI For motorcycle GY6-Style engine Scooter DirtBike ATV | eBay

Please note that the jetski will rev out unhindered, so you need to get an RPM and limit it to it's maximum otherwise you'll blow the damned thing.

i can email the wiring diagram for this unit directly to you.
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Old 05-07-2013, 09:39 AM   #10 (permalink)
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Quote:
Originally Posted by viper000 View Post
here is the CDI i purchased off Ebay at this site

High Performance Racing CDI For motorcycle GY6-Style engine Scooter DirtBike ATV | eBay

Please note that the jetski will rev out unhindered, so you need to get an RPM and limit it to it's maximum otherwise you'll blow the damned thing.

i can email the wiring diagram for this unit directly to you.
Love to have the wiring diagram Viper000. Sent you a pm.
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