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post #1 of 14 Old 09-17-2012, 05:25 PM Thread Starter
 
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2000 big bear 400 no spark

First of all this is my first post here I have been reading posts for quite a while now and everyone seemed to have at least some idea of what they were talking about so I joined. Now for my problem. I bought a 2000 big bear 400 4x4 from a "friend" very cheap. It was not running at the time(and still doesn't). He told me he was riding and it just died. He said he took it to a shop and they told him it needed a new wire harness and stator. When I got it home I pulled the racks and fenders off and replaced the bearings in both front hubs and the rear differential and rebuilt the carb. I checked the resistance on the pickup coil and couldn't get it read as a dead short. I replaced the stator and pickup coil with a new ricky stator unit. I also stripped all of the tape off of the wire harness and checked all the wires. The only wire that was melted was the small ground wire going from the frame ground by the battery to the coil. I ran a new wire for it and soldered all connections. I checked all switches and connections. I still have no fire on the orange wire going to the coil. In fact, when i check it with an ohm meter it reads as a ground. Everything else in the electrical system functions as it should. Could it be the cdi? btw the reason the ground wire was melted was the connector broke off the end of the ground wire going from the battery to the frame, so the way it was hooked up everything on the bike (started, lights, etc..) was grounded through one small (14 guage?) wire. There isn't a short anywhere in the wire harness. I have inspected it thoroughly. I can unhook the connectors from the cdi and hook them to ohm meter and black/white wire (runs to kill switch) shows ground when in off position and no connection when in run position. If i hook ohm meter to corresponding pin in cdi it shows a slight ground all the time. Here's what I'm thinking. When the ground wire broke the bike shut off, then when the po tried to crank it it somehow tried to ground back through the cdi and possibly destroyed it. So my question is, has anyone else had this happen to them and if so did replacing the cdi resolve the issue?
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post #2 of 14 Old 09-17-2012, 08:58 PM Thread Starter
 
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Also if anyone has an identical bike and could check and see what kind of readings they have at the cdi it would be much appreciated

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
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post #3 of 14 Old 09-25-2012, 01:23 PM Thread Starter
 
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anyone?

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
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post #4 of 14 Old 10-01-2012, 10:19 AM Thread Starter
 
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Anybody work on their own stuff around here?

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
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post #5 of 14 Old 10-01-2012, 12:28 PM
 
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i have the same problem with my grizzly 600 im at buying a new cdi box everything else is brand new electrical
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pickensthumper (10-02-2012)
post #6 of 14 Old 10-02-2012, 10:49 PM Thread Starter
 
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Thanks! Let me know if it works

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
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post #7 of 14 Old 10-09-2012, 01:01 AM Thread Starter
 
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replaced cdi. runs like a champ now

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
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post #8 of 14 Old 10-09-2012, 08:19 AM
 
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Glad you got it fixed! Sorry I couldn't help.

2012 Big Bear 400 (Green)
Full Ricochet skids
Kolpin Gun Boot w/transport case
Fat Max box
IPI front bag
27 Zillas
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post #9 of 14 Old 10-28-2012, 11:02 PM
 
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I have the same problem except I was actually riding mine when the ground wire from coil burnt all the way to frame ground at battery. Smoke everywhere I thought it was on fire. A relative of mine told me the only way to safely correct the problem is to replace everything electrical but it is hard to put $1000 in a 10 yr old atv. I have replaced the coil and pieced the wiring harness back together but no spark. Not sure where to go next.
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post #10 of 14 Old 10-30-2012, 12:54 AM Thread Starter
 
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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
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post #11 of 14 Old 10-06-2013, 11:33 PM
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Hi, I'm looking for one of these CDI units for our 2000 400cc Big Bear. Seems the only ones I can find online are for 1999 or 2002 models, not 2000. We were quoted $500 from a dealer! Can I ask where you sourced yours? The part number on ours is 4SHM-010
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post #12 of 14 Old 10-15-2013, 04:00 PM
 
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That is not the same part number as on my 2000 big bear 400 CDI. I would goto one of the parts houses that give OEM numbers and lookup your bike by the model number under the seat. That will give you a real part number to lookup (my factory number for a 2000 was 5FU-85540-00-00 and $270ish shipped.). However, a new CDI did not correct my issue - so if I have a good one after getting the quad running I'll let you know.
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post #13 of 14 Old 10-16-2013, 05:46 PM
 
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To add to this, i recently worked on a friend's 2005 400 kodiak with the same problem, traced it to a bad pickup coil, replaced and still no spark.

Nothing happens on the output of the CDI to the coil.

The CDI is supposed to get tested on a working quad sometime this month, yeah he's pretty busy...

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Yamaha Kodiak 450 2007 IRS
1.25mm Clutch Shim
8x 15.6g Clutch Weights (drilled 660's)
Reverse and Full-Lock Limiter Bypass
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post #14 of 14 Old 10-17-2013, 01:27 AM
 
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Quote:
Originally Posted by daver18qc View Post
To add to this, i recently worked on a friend's 2005 400 kodiak with the same problem, traced it to a bad pickup coil, replaced and still no spark.

Nothing happens on the output of the CDI to the coil.

The CDI is supposed to get tested on a working quad sometime this month, yeah he's pretty busy...
My issue was bad pickup coil and blown CDI. We had swapped the stator with a new (cheap) eBay part and the resistance I the pickup coil was only 400 vs 500 (and not convinced it wasn't wired reversed).

Original pickup coil was good so used it, no spark. Added the new cdi back in and issue resolved. Spoke to Mike at Ricky stator and decided that bad rectifier/regulator most likely cause the burned up ground wire so having replaced that, I should be good.

Sadly my old CDI is toast so can't help anyone out with a working one.
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