Hi all!! new to the forums here. Having an issue with no spark. Let me break it down. Rebuilt the engine (broke piston & seized pin bearing on crankshaft), ensured timing was correct by lining up cams with timing chain per the clymer manual. Installed used wiring harness (dog ate the old one). New parts: ignition coil, stator assembly, iridium spark plug, battery and used cdi (guaranteed to work).
Engine turning over with start button in neutral. Getting 12 volts on red wire to ground at CDI. Ohmed wires on pulser coil (190 ohms) and reverse coil (1.2 ohms). Not getting input (1.4 VDC) and output (200-400 VDC) on coils to ignition coil. Anything I maybe missing?

 

did the wiring harness have any safety features ie kill switch, tether also easy to look over but are you grounded everywhere

 

No kill/tether was installed. Checked all the grounds and seemed to be good. Cut the black wire on the CSI to ensure no groind in through cdi

 

If no tether switch was installed did you tie the wires together? Cutting the black wire from the cdi just eliminates the kill circuit,but do you show voltage from the cdi to the coil? If not then the used cdi could be suspect. Plus check coil primary(tab to ground) should show small ohms resistance and no zero out/short to ground. Same thing on secondary(coil tab to wire end,plug cap removed) should be around 6k ohms as most coils show,plus the resistor plug cap should show close to 5k ohms resistance. Also see if you have spark from the bare wire to the engine. Not unusual for caps to short out or even coil wires to break internally either.

 

Thanks OPT I'll check those things here in a bit and fill you in.

 

I believe the cdi is faulty. No pulse coil voltage across white/blue and no output coil voltage across white/red and white/blue. I did tie the tether plug wires together by jumping across the plug and nothing. Did ohm test on ignition coil plug wire to ground and have 6k ohms. Originally tested the plug cap and was getting 20 ohms. Pulled the resistor out of plug and was getting 5k ohms. Cleaned up the brass screw and put resistor back in and now getting 9k ohms on plug cap. That is out of range. Total 15k ohms from cap end to coil ground. Is that too much resistance?

 

Too much resistance on the cap.Plus this is a special plug cap. Shows around 25 bucks,coil assy around 50 bucks or so on Cycle Parts Warehouse http://www.cyclepartswarehouse.com/f...&fveh=5629,but considering shipping might be better to get one on ebay,that is if you don't want to replace the whole coil assy.http://www.ebay.com/itm/OEM-POLARIS-SPARK-PLUG-CAP-3088054-/251648023823?pt=Motors_ATV_Parts_Accessories&hash=item3a97641d0f&vxp=mtr Plus if this is a "guaranteed" used cdi,I'd try to either get a replacement or spring for a new one.

 

Will do OPT. On order new plug cap and new CDI. I'll keep you posted on the outcome. Thanks!!

 

It was the "guaranteed" CDI unit that was faulty. New Procom CDI unit and spark plug cap and she is now sparking!! Thanks again OPT!!

 

Glad you got it fixed! Just my I would have gotten a replacement oem cdi since it was guaranteed,but that's just me.. Hopefully the Procom cdi can hold up for you. Some have had problems with them.