My 96 Big Bear has spark problems. A friend of mine gave it to me and it needed a top end overhaul. It did run but you could only start it with the pull cord. Once it was warm it would start with the elec. We put it together and no spark with the elec starter. If I pull it by hand I get spark. I have a shop manual and did all the tests for the ign and it seems to check out. The only one out of spec was the spark plug cap. Specs were 10 k ohms and mine is 11 k ohms. I asked a tech at the dealer and he said if the starter is draging it can pull the volts down and you will not get spark. I tried to start it with jumper cables direct to the starter with a car battery. Still no spark. I have cleaned all the elec connectors and tested all the grounds. Anyone have any ideas. Thanks Dan

 

If it were mine I would pull the starter and take it to a good starter repair shop to have them test it on their machine. My truck had the same problem and the repair shop after bench testing sold me a new starter that ended that problem. I also used a jumper battery to try and increase the amps required, but, had the same results as you did. Tom/Idaho

 

I took the starter to the elec shop and they said it was fine. I am going to check all the safety interlock switches and relays.

 

I have the exact same problem mine is a 2000 big bear and it wont even crank with the switch but it will start with the pull cord. I even crossed the poles on the starter solenoid, it will turn over but not start. I replaced the solenoid still no go. I even put a set of boostercables on and still no go. The only way to start the machine is with pull cord. anyone with ideas would be great. There are 3 relays under the rear rack over the tool box they are the neutral relay reverse relay and Starter cut off relay. could any of these cause this problem?

 

Does anyone no if you can test the mag output before the cdi unit? This qaud was used on a farm and spent its whole life ideling in a field. It got so hot you could hardly stand to ride it. could the heat weakin the magnet in the flywheel, and require it to turn faster to put out spark. The friend who gave it to me said he had the stator replaced once and the mechanic told him the heat had killed it.
Thanks Dan

 

get a manual and it will give you the ohm specs for the magneto and stator. that will tell you if its bad.

 

I have the factory shop manual. The source coil and pickup coil check out with the ohm test. I emailed a company that sells stators on ebay. I told him my story and he said replace the stator. I do not want to throw parts at it unless I know it will fix it.

 

I called Ricky stator and told them my story and he said that it was weak and needed the extra speed to spark. I replaced it and it started right up. It cost a $150 and came with a one year warranty. He also told me the factory manual specs were to large of range.