99 conquest no spark

[wnh8x8]

I've recently acquired a 99 conquest with a kawasaki fd620d engine. It was running when parked (about a year ago), but now won't fire. I started with a general cleaning, including pressure washing the engine bay, cleaned the carb, replaced the old fuel, added "sea foam" fuel treatment, charged the battery, etc. It turns over, but doesn't fire. Before tearing into the ignition system, I'm searching for something I might have overlooked.

I've confirmed the transmission is in neutral and set the brakes. The oil level reads full. Haven't checked the fuses yet or looked for other loose wires, but, without a manual, those are all of the things I know to do. Does anyone know of any other probable "fixes"?

[Toys4Me]

Have you done a visual spark test?

[guyfox]

Check out the home page for a copy of the manual for argo,,,

http://www.6x6world.com/forums/content/section/421-argo-manuals.html

And if that is no help then I have a copy of the FD620 manual. PM me your e mail and I can send you a copy.

[Rock Doctor]

Air + Fuel + Spark
Thats all you need
If it was running when it was it was parked a yr ago, Air should be fine.
Pull the Spark Plugs, plug them back in their boots, and set them on the engine in such a way that the SP threads are grounded to the engine. Crank the engine over, and watch the SP's for spark (Don't touch the SP's). If you have Spark, dribble a little 2st oil in the Cylinders and put the SP's back in.
When you say you "Cleaned the Carb", what did you mean? Did you change the Fuel Filter? Can you hear/feel the Fuel Pump run when you turn the key on? I would suggest that you should take your Carb apart and clean it properly....... There are several little ports/jets that are probably plugged off.

Try not to run any of that old fuel.

RD

[rapidroy]

To do a real quick spark and comp test just dribble a little gas straight into the carb and crank it over, if it fires then dies your gas shutoff sol is probly stuck. Rock Doc's got a fix for that... RR

[wnh8x8]

I used a test light that goes between the spark plug and the wire. I'll pull the plugs today. I found the fd620 manual on-line, but the ignition section walks through testing individual components. I don't mind doing that, but am thinking two things: first, there may be some safety switch preventing the spark. I read in a newer argo manual that the low oil sensor can prevent spark. Also thought maybe the gear shift had a safety switch to prevent starting in gear (I started an older machine in gear a few times and had it roll away from me). Is there a "dead-man" switch on the seat? Maybe a fuse?

Second, the hour meter reads only 75 hours, and I know the original owner. It was running when parked and I doubt anything major (mechanically) happened during the year it was parked. I'm just wanting to eliminate all the simple answers before I start taking the electrical system apart.

As to the carb, I disassembled and soaked then blew all the orifices out with air. Had a heck of a time getting the rubber gasket back in the groove between the top plate and the bowl. Haven't checked the fuel pump, yet, but gave it a shot of starting fluid to see if it would hit. So far, no luck.

Thanks for your input!

[wnh8x8]

fuel shutoff sol

By the way, when I took the carb off, I noticed there was no fuel solenoid as pictured in the FD620 manual. The prior owner mentioned that his mechanic put a new carb on the engine. I'll look again to verify that I just didn't miss something.

[Rock Doctor]

There are no safety switches, other than the Anti-Backfire Solinoid, and that sounds like it's been removed from your machine.
I'm no small engine guy, but I think it's importand to carefully clean all the Jets, Orifices, Holes in the carb components. Maybe you did that. I like to poke a fine Torch Tip Cleaner through the holes to make sure they are clear.


RD

[Rock Doctor]

Sitting that long, it may have a blockage in the fuel system too.
Pop the fuel line off at the carb, and carefully turn the key on...... May want to direct fuel line towards the wifes cat, or into a gas can. Quick way to eliminate that possible issue.

RD

[Adondo]

Sitting that long, it may have a blockage in the fuel system too.
Pop the fuel line off at the carb, and carefully turn the key on...... May want to direct fuel line towards the wifes cat, or into a gas can. Quick way to eliminate that possible issue.

RD

Which issue? The wife's cat?!?

As far as safety switches, (if any) those just about always interrupter the starter circuit rather than kill the ignition.

Just about all small engines have a kill wire. One circuit of a typical law mower key switch (what most 6x6's use) make a connection to ground to kill the engine. Make sure that kill wire is free and un-shorted. If it touches ground anywhere along its length: no spark.

Mower key switches have 5 terminals: incoming battery plus, switched power, starter feed, (goes battery plus when held to start) a ground, and the kill wire connect.

There are two contact sets when the key is turned. One contact set OPENS the kill wire to ground circuit, the other CLOSES to power on switched accessory items. A 3rd circuit momentarily CLOSES from battery plus to starter solenoid.

[wnh8x8]

RockDoc, I watched your YouTube video on carb cleaning and did almost exactly as you did. Pulled spark plugs and checked fuses and for loose wires this pm. Nothing. I guess I'll have to pull the ignition parts out as per manual and test 1 by 1. What a pain.

[ARGOJIM]

Before you go to crazy pulling things apart. The ignition switches do fail some times , check that the fuses are all good and if so disconnect the yellow wire from the ignition switch and supply power to the yellow wire then crank engine, if you have spark it's in the switch. If not you will have to look further, our 94 needed the large harness plug redone due to connection issues where it would shut off for no reason and restart run fine for a while after shaking connector.
There is a ten amp fuse that controls the ignition module and fuel solenoid.

[wnh8x8]

Spoke with a local small engine mechanic today. Since no spark at either plug, he thinks I've got a loose wire or bad connection "upstream" from the coils. Still looking.

[wnh8x8]

Broke down and took it to a mechanic. Still waiting on an answer. I think it may be the ignition switch as you guys suggested, because the fuel pump wasn't running either when I turned the key.

[Madman]

Mine did t have any spark it ended up being a fuse 1996 conquest