I previously posted questions about why my atv wasn't firing. I smoked the clutch diode in the process of troubleshooting the problem w/o a manual.

I've since gotten the manual and a nearly complete wiring harness from a parts ATV. I still am not SURE what the problem was....but it's idling for me now and I am rejoicing.

Here is what I did/found out:

I installed almost all the components from the ebay parts harness(everything but the stator and the rectifier).
It still did'nt fire....So after shedding a few tears I re-evaluated what I had done....
In every motorcycle I've delt with at this level - the kill switch grounded the ignition which means you make sure the two wires going to the kill switch arent shorted to make sure it's not the cause of the no-fire problem.
The bike wasnt firing but turning over fine - so I pulled the kill switch apart and confirmed that it wasn't shorted. Still got not fire - so I left it apart to confirm it wasn't shorting while I checked the other components and ended up ording the parts.

When it still wasn't working for me - I looked the various diagrams of the ignition system over again and noticed that it looked like the circuit that supplied power to the CDI and in turn the coil had the kill switch completing the circuit. So I shorted the two leads and got a nice spark.....

SO - what this indicates is that the kill switch wasn't making the circuit...It sure looked healthy and clean when I pulled it apart but it looks like that was the whole problem.
OR some other component I swapped out was at fault in addition to the switch and I fixed that too. Maybe I'll swap all the parts out one by one and find out if one of them really is bad.

Nahh - I'm going riding!!!!

 

Hello, I was wondering if You did any other tests on Your kill switch prior to taking it apart? I checked Mine according to the manual, and it tested OK. I don't trust those manual tests very much, the brand new coil I bought tested the same as My old one, which the manual test indicated a bad coil. Was Your coil bad? So far I have bought a complete wiring harness with a CDI and alarm box and a new coil, still no spark. I bought another alarm box and CDI off eBay, I'm waiting on the CDI in the Mail before I mess with it any more. Have fun with Yours.

 

The only thing I did to "test" the kill switch before taking it apart was to vigorously operate it back and forth while turning it over and watching for spark.