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post #1 of 10 (permalink) Old 04-08-2019, 04:25 PM Thread Starter
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Ignition Issues

I have a 1999 Xplorer 300.
It will not run. I bought it not running.
When cranking over, it backfires out of the exhaust and intake.
Using a timing light, I noted timing mark on the flywheel is about 12 degrees past the stationary mark. This is done with the spark plug removed and grounded to the engine. It does give a healthy spark.
I have tested the mag coil, ignition coil and spark plug wire and all the ohm values are correct.
Is this normal for the timing to be retarded during cranking or is this an indication of a timing issue.
Thanks in advance for any input and advice.
Denny
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post #2 of 10 (permalink) Old 04-09-2019, 06:02 AM
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Try a new spark plug - old plugs are harder to fire and will cause a delayed spark - or the flywheel key sheared and the spark is out of time in relation to the position of the piston - there is a probability of another cause, but always start with a new spark plug.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
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post #3 of 10 (permalink) Old 04-09-2019, 06:49 AM
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If a new spark plug does not solve the issue, I'd check to see if the flywheel sheared off the key. What you're seeing doesn't sound right, but I don't have a manual, so that's the best advice I can offer
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post #4 of 10 (permalink) Old 04-10-2019, 03:04 PM Thread Starter
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Thank you for the input.
I should have mentioned this
I tried 2 new plugs. BR8ES. With or without the plug, the timing is the same delayed.
The keyway has no issues. I did replace the CDI module.
I am checking the timing with the recoil starter housing off because you can't see the mark with it on as it is past the opening. I am turning the engine over with no plug installed and a drill and socket turning it about 300 RPM.
Also, I did find 1/2 of one magnet on the flywheel broken off. I epoxeyed it back on in the same location. There was no damage to the stator. With the 3 machine screws loose on the stator, I have it fully advanced. ( as far counter clockwise and it will go.
Any ideas what else it can be?
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post #5 of 10 (permalink) Old 04-11-2019, 07:02 AM
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I think you need to recheck the flywheel key. Something seems off there to me.
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post #6 of 10 (permalink) Old 04-14-2019, 07:47 AM Thread Starter
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I have rechecked the keyway and it is fine. ( no wear).
I rechecked the stators and there is only one way they will fit. Wanted to make sure I did not install them incorrectly.
anyone have any other ideas?
Thanks
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post #7 of 10 (permalink) Old 04-14-2019, 07:54 AM
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Start at the beginning - how much compression does it have?

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

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post #8 of 10 (permalink) Old 04-14-2019, 07:58 AM Thread Starter
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115 psi.
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post #9 of 10 (permalink) Old 04-14-2019, 08:01 AM Thread Starter
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I am turning the engine over with the spark plug out using a drill connected to the flywheel nut. Turning around 300 RPM. I did this because with the cover on over the flywheel, I could not see the timing mark in the timing hole. After removing the cover I found the mark around 15 degrees past the hole
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post #10 of 10 (permalink) Old 04-14-2019, 10:37 AM
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115 is a little low, but should be sufficient to get it running

There is 4 marks on the flywheel - 3 marks close together and counter clockwise from the 3 marks, the TDC mark - with the flywheel turning clockwise; the first mark is at 27 degrees BTC, the next mark is 25 degrees and the third mark is 23 degrees - the next mark is TDC - paint the TDC mark white and the 25 degree mark yellow or vice versa.

Without looking at the flywheel, put the engine on TDC - insert a soda straw into the spark plug hole and rotate the engine by hand until the straw stops rising indicating the piston is at TDC - the flywheel key should be on the top side of the crankshaft in a parallel line with the cylinder and the TDC mark should be visible in the inspection hole.

Spark should occur at 25 (plus or minus 2 degrees) degrees before TDC @ 3000 RPM - for starting, the spark should occur any time before TDC - the ignition curve is electronically controlled and maximum advance may be greater or less depending on the design of the components.

From the manual:
1. The ignition timing check hole is in the starter recoil/magneto housing. Remove the check plug.
NOTE: The ignition timing marks are stamped on the outside of the flywheel. Ignition timing must be inspected
with the engine at room temperature (68F I 20 C).
2. With the transmission in neutral, start the engine and set engine speed to 3000 +1- 200 RPM (3500 200 RPM for ES33PF (330 cc), EH42PL (425), EHSOPL (500)).
3. Direct the timing light at the ignition timing check hole and check the ignition timing. NOTE: Do not allow the engine to warm up. The timing will retard approximately 2 when the engine is warm.
*Actual advance point may vary by several hundred RPM either above or below 3000. Use the point of maximum
advance when checking ignition timing.

I hope you find this useful.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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