Female plug coming off the switch assy? Mine has a male plug. The quad side of the harness is the female plug. This could explain why I can't find a replacement switch. Thanks for the info and schematic attempt That works out pretty well and I hope will get me on the right track to rebuild this dang switch.

*********pay no attention to the pin count in the one pictured because this is the one I am trying to re-wire, so it only shows 5 wires in this pic, but as you can see, it's Male pins.*********

SWITCH SIDE:

 

Pics:

The switch:



The kill switch and starter button half



The headlight portion

 

YAY!! I am not mad! been tearing my hair out with my quad that goes under the name of Protrax 250d but is the splitting image of your bikes.

I bought the bike a wile back and after rebuilding the wiring from scratch i got it running with a single output cdi but i seem to have the same prob as far as you ride the bike for about an hour or 2 then is dies with no chance of starting again.(Evan tried starting it wile being towed) Leave it for a few hours and it will start very easily. the mystery box you talk about does not seem to have anything to do with the ignition circuit as mine does not have one and "when running" runs very well i was wondering if you could post the pin out on the duel out put cdi that you got i have a funny feeling that if i wire my cdi in the same order it might just work..


Shots guys!

 

Oo... as a foot note the only wire you should have power from the battery is the red yellow going to the starter relay. The ignition circuit gets power from the coils
so if you are testing the ignition, test from the cdi power input. (on mine its the red black wire)

Also the kill switch goes to earth as well as the starter relay so the switch gear on mine has two earths wires both common to most switches so you get 3 wires for two switches if that makes sense hope if helps

 

Was reading the Honda forums and they seem to have similar conditions and several have traced the issue to faulty spark plugs (which is where I have been grounding my ignition tester). Something to do with possible cracked porcelain. I'm gonna throw new plugs in and see where I'm at. Hell, I might get lucky.

 

Got an update....spark plugs seemed fine. I took the trigger wire off the driver coil pack and T'd it to the passenger side and she ran like a champ. This was using a new ebay CDI box. It apparently does fire both coils at the same time.

 

I know we talked about this before...........the CDI's all looking alike, but not actually alike at all internally. I bought a CDI off eBay for a Honda CMX250 (CMX125 works as well). It has the correct internals for a twin cylinder engine like we have. That fixed my problem of no spark as well. In case the single fire splice job ever gives you any more trouble, you can go that route. I think I found it for something like $25 or so. But some crazies on eBay were asking upwards of $75+ (crazy!!!)

 

Im pretty sure that Honda CDI changed over the years. I didn't really read up on it but I coulda swore I heard them referring to an older design and a newer design.

 

I have the same ATV. Been working on it off and on for a couple months. I got it in bad shape and I am in the process of a top end rebuild. Got a new cyl in today. Getting new pistons, rist pins, and rings in a couple days. I had several wireing issues on mine where PO ripped and cut wires. I'll see if I can find some of the info i dug up on it.

 

My no spark is moving around depending on CDI I run. I put it around the back of the shop for now. I got an 07 Honda CDI and I think I need one from the 90s. I'm gonna order a new one and see if that fixes it.