Join Date: Sep 2012
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Sounds like you had the exact same thing happen to your bike that happened to mine. You will need a good ohm meter and a test light wouldn't hurt either. I ended up stripping the wire harness from the cdi to the coil. Checked the insulation on all the adjoining wires in the loom to make sure the ground wire hadn't melted through any other wires. I then ran a new ground wire and soldered all of the other grounds to it. I replaced my stator because I assumed it was bad without really doing any research...idiot mistake on my part. Turns out there was nothing wrong with my stator or pickup coil. There is a way to test the pickup coil with an ohm meter but I don't have the exact #'s right now but I'll try to remember to grab my book while I'm at the shop tomorrow. In the meantime check all the wires and make sure they aren't shorted out anywhere. With the switch on the orange wire going from the cdi to the coil shouldn't be grounded. If it is try disconnecting the wires from the cdi and checking orange wire for continuity. Also check you switches and fuses just to be on the safe side. You can check the kill switch with an ohm meter. Check continuity between the black and white wire that plugs into the cdi and ground. Check continuity with the cdi unplugged and then with it plugged in. If the switch is functioning properly and the black and white wire shows continuity with ground while plugged into the cdi AND the orange wire is showing continuity with ground then I would be willing to bet it is the cdi...which is close to one of the most expensive things on the whole bike. I managed to score one for $50 from a guy that was parting a bike out. If you suspect the cdi is the problem try to find someone that has a bike like yours with the same cdi and swap them and see if it fires.
2006 Grizzly 660
-686 cylinder, 11:1 high comp piston, stage 2 cam,+4 stroker crank,4 kodiak weights,1.5mm clutch mod
warn bumper, wild boar rad relocator, 30" sbacks on 14" itps.
2000 Big Bear 400 4x4
1985 Honda ATC 250sx
200x front fork conversion
1981 Honda ATC 185
200cc cylinder, high comp piston, 200x cam
Honda atc 110, 200s, 200es, 200, 200x-sold
Polaris sportsman 500H.O. D.U.S.E-sold
Polaris explorer 400-sold