I got her to crank, it was a bad ground connection for the starter at the Stator cover. I however have no spark. I have done all the tests and my results are below. Any help is VERY appreciated.

I have replaced BTW - Solenoid / Voltage Regulator / Ignition Coil / Spark Plug / CDI

I have a 5-Pin CDI

Method 1) Unplug the CDI and remove the kill switch pin in the CDI connector on the wiringharness. The pin is held in with a spring tab on the pin itself. You'll have to probe into the connector and push this tab in order to extract the pin. Plug the CDI back in (kill switch wire dangling) and see if you have spark. No Spark


Method 2) Unplug the CDI. Turn on the ignition switch and set all kill switches to the run position. Use a meter to measure resistance in of the kill switch pin in the wiringharnessconnector to engine/frame ground. If the reistance is infinite on the 100K ohm scale then your kill switches/kill switch wiring are OK. If you measure zero ohms then you have a kill switch/wiring issue. All Infinite, and switching them grounds out - seem OK


The other inputs your CDI needs to make spark are AC Ignition Power, and the Trigger signal. Do the following:


1) Unplug the CDI. In the wiring connector measure the resistance of the AC Ignition Power pin to the Ground pin. You should see 400 ohms or so. What do you measure? Infinite


2) Measure the resistance of the Timing/trigger pin to the ground pin. You should measure 150 ohms or so. What do you measure? 145


3) Leave the CDI unplugged. Set your meter to measure AC volts on the 100 volt scale. Measure the voltage on the AC Ignition Power pin to the ground pin while cranking the engine. You should see 40 to 80 volts AC while the engine is cranking. What do you measure? 25


4) Set your meter to measure AC volts on the lowest scale you have. Ideally this would be 2 volts but many meters don't go down this low. In that case use the lowest scale you have. Measure the voltage on the Timing Trigger pin to the Ground pin while cranking the engine. You should 0.2 t0 0.4 volts AC. What do you measure? My lowest is 200, read 0


Now for measuring the output side of the CDI:


A) Leave the CDI unplugged. In the CDI wiring connector measure the resistance of the Ignition Coil pin to the ground pin. You should measure less than 1 ohm (but not zero ohms). What do you measure? 1.6


B) Plug the CDI back in. Set your meter to measure AC volts on the 20 volt scale. Set all kill switches to the run position. Crank the engine while measuring the voltage on the Igntition Coil pin to ground. Poke through the insulation of thewire if you can't probe the connector. Lowest I have is 200, did nothing, stayed at 0


Caution: There should be moderately high voltage spikes on this wire. Make sure your fingers are not part of the circuitry. Don't touch the probe lead tips while doing this test.


What you should see is a lot of random numbers with lots of zero values as well. This is because the meter may catch all or part of the spark event voltage, with a lot of nothing in between. Describe what you see.


Note: Using a meter to measure this point produces highly variable results depending on the meter. What you really need is an oscilloscope, but most always a meter is all that is available. We have to do the best we can with what's available. Describe the meter results as accurately as you can - there is information there to chew on....

 

Any help would be extremely appreciated. I don't want to just throw parts at it, and the boy is really missing it. Thanks fellas.

 

Well, you are getting contradictory results on the power coil, no way should it be open circuit. Trigger/timing coil should produce an AC voltage, but if your meter is 200v min, it may not pick it up. If your results are correct, you have a stator problem, but that bad earth could have toasted your CDI, nothing is more likely to burn the CDI out than a bad earth to it.

 

It was the stator. She's running perfect now.