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I bought a 99 Grizzly 600 that had just quit running to repair and boy am I getting my <insert word here> kicked.

I am using the Yamaha service manual and have followed their igntition system troubleshooting strategy.

I tested the ignition coil primary and secondary coils and they check out within specifications, have a new coil I swapped no change even after the stator replacement.
I had a bad ignition pickup coil on the stator (Open between red and white) the replacement stator assembly resistance values check out inside the specs in the manual, I checked the ignition supply coil with a test light while cranking and it lights up as well as checking the resistance. So, new stator still no spark.

I checked the kill switch with a test light at the cdi plug on the black/white wire and it works as it should

I checked the brake switch and it works as it should tested at cdi plug on the green and yellow wire at the cdi

Tested Ground wire at cdi, .7ohm, voltage dropped while loaded and wire tests ok.

Neutral and reverse indicators working while moving the shifter to their positions.

New battery

Ignition switch seemed to be ok, replaced anyways when i ordered the spare coil. No change

Removed every wire connector on the bike and cleaned them out with air and applied dielectic grease to all connectors in the ignition system and more. No change.

Re checked my work to this point and ordered a new cdi, installed it. No change.

Just finished going over everything again in the manual test procedure and looking at all the wires that go to the cdi and cant find anything that would be preventing the ignition system from operating.

Any Suggestions? Any help would be appreciated. Is there a way to test the pickup coil while cranking.
 

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Swap the wires for the pickup coil. I usually do this at the connector. I have seen them be wired wrong, right from new. See if that works.

If a pickup coil is not wired correctly, it will not give a signal to the cdi to give spark at the plug.
 

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Swap the wires for the pickup coil. I usually do this at the connector. I have seen them be wired wrong, right from new. See if that works.

If a pickup coil is not wired correctly, it will not give a signal to the cdi to give spark at the plug.


I backed them out of the 4 pin connector at the stator wires and swapped them still no spark.
 

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Wow Northcountry that's pretty intense troubleshooting, couple of things you could check, spark plug lead separated internally at cap from pulling on & off, bad plug, bad ground at plug when turning engine over, you seem to have everything else covered, maybe start at the plug & work back from there checking wiring & resistance, can you attach the volt meter to the power side of the coil & crank it over to see if it's getting robbed of voltage & not getting it's 12v, any wires that go around bends could stretch & have an intermintent break in them, when doing resistance tests give all the connecting plugs a wiggle to see if there's a break, now do something different like having the h/bars on full lock or so & see if there's a change, if the stator is not genuine it's not unheard of to test good off the bike but earth out when tightened up, the best advice you can get is to take a break off it for a couple of days & start fresh or you will end up turning to the bottle & start seeing "things" :surprise:
 

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I don't see that you replaced the spark plug.

You pickup and source coils meet these spec's correct?
 

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I don't see that you replaced the spark plug.

You pickup and source coils meet these spec's correct?
New plug but wouldnt matter since no spark from coil with spark tester.

Found out what it was, I put the stator in one night at about 2am and I installed the pickup coil the wrong way, im supprised the cover went back on, its hard to trigger spark when your magnet is mis aligned with the coil. Fired right up, then realized there is some sort of bushing that fell off the bendix starter drive or cover once I had it all back together so now i get to take it apart again! Also while it was running I found out its got a knock and reverse didnt engage, but i adjusted the rod and its ok now. So now I get to tear down the engine that I was told just had a piston put in it! Guess its full restoration time over the winter.
 

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Thanks for the update. Your detailed trouble shooting will help other members in the future.

No shame...There have been several other members that installed the pickup coil wrong or wired it backwards.

Maybe you just drop one of the case dowel pins.
 
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