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2003 330 2x4 no spark.

18K views 11 replies 5 participants last post by  Naturalblaque  
#1 ·
Alrighty so hello all new member here. So I picked up an 03 trail boss 330 from a guy for dirt cheap it was running but carb was leaking and the ignition coil was on its way out. It sat for about 3 months due to work schedule etc. My dumb ass didn't take a pick of the wiring in the front before disconnecting and now I have no spark. I was wondering if anyone knows how the ignition coil should be grounded /installed. I know the blue white is power but After that I've tried every combo I thought. Now. Full disclosure the guy spliced this and that up front so who knows what the hell combo is actually right. I've looked at the wiring harness diagram but I can't make out what's what for grounding and how. Any help would be massively appreciated.
 
#3 · (Edited)
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#5 ·
Welp so far no luck everything I could identify brown I put on the top or bottom bolt on coil still no luck. What are the absolute bare minimum wire connections to verify spark. Don't know if that's too broad of a question or not. I'm going to go tAke a few pics of what's going on in the wiring harness to try and show what the hell I walked into
 
#8 ·
It sure looks to me like the tripple brown wire eyelet end is just hanging loose??? Right next to the yellow insluator??
 
#9 · (Edited)
This might not be an issue, but there is a red/wht wire (07 on the wiring diagram) red/wht is hot when the handlebar switch is in the run position (red/blk is hot as soon as the key is in the run position) - that has nothing to do with running, but I would try to find the correct wire to plug into
plugged into a red/blk wire - the red/wht is supposed to be plugged into a red/wht that goes from the SSCB to......

This post is messed up - don't know what happened but the pics, graphics and text was truncated. I don't have time to re-do it now - I'll try again tomorrow
 
#10 ·
Second try:

149106


The red/wht wire at the CDI unit (two of them on the SSCB plug terminal 'K') that is plugged into the red/blk wire might be an issue - unplug the two wires and check the voltage - red/blk should be 12v with the key switch in the on position and the red/wht wire 12v when the key switch and handlebar switch are both in the run position.
149107


The red/wht wire should go from the SSCB to the brake switch directly below it. Now there should be an orange wire plugged into the other side of the brake switch, but back to the red/blk wire......

Starting with the key switch there are two r/b wires #22 and #30 both go from the key switch to the LH switch.
Provided you are actually working on a 2003 330 Magnum 2x4 and it's not the HDS model, these are the only red/blk wires on the vehicle.
Is there a junction board on the front anywhere? That red/blk wire hac to plug into another red/blk somewhere unless it's been Frankenstein'd to another wire like the orange wire?
149108

149109


I think one of the questions was "What is the minimum wires needed to get spark?"

The black wire is not needed - it is the kill wire
The red/wht wire (12v DC) plugged into the brn/red wire of the CDI box
The wht/red, wht and brn
The blu/wht triggers the coil to spark

The spark can be killed by connecting blk to brn or removing voltage from the brn/red wire

149110
 
#11 ·
Having the same issue. Traded a mini bike for a 03 trailboss 330 last year. The guy cut everything and was using the pull start. Bought, pulled the fly wheel and there was mud everywhere. Cleaned all the grounds and the rust from the flywheel, fixed pull start and it ran until I decided to ride it. It had intermittent spark. Bought new cdi, coil and spark plug and still no spark. Checked the etc switch which seems to be working fine. Checked the air gap by the magneto to me sure it was withing tolerance i then it was .016-.030 and i left it at .016 because its kinda hard to set. I unplugged the kill wire. This thing was sitting in the rain for years. Any suggestions.? (No not taking it to the junyard just yet.)
 
#12 ·
This is what the wires look like so far and yes this mess ran fine with wires like this. Main harness is too expensive and it doesnt have to be pretty just funtional.
 

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