I got a non running 1997? 250 2 wheel drive Cat. Engine is good and body is good but wires are messed up bad. Just wondering if a Suzuki cdi would work since they are supposed to be the same. Easier to find than AC and the listing price for the cdi is like 273.00 which is crazy. Does anyone know? What about difference in 250 vs 300 motor?

 

The CDI is rarely the cause for electrical problems; however, if the CDI is suspected, substitute another CDI unit to verify the suspected one is defective.

NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI peak voltage test and/or perform a continuity test of the wiring harness from the CDI connector to the CDI unit.

NOTE: The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

I think that if the peak voltage is within range and the wiring hooks up then it would be fine. Your RPM limiter may have a different point. If the 300 is higher and you rev the 250 to that point you could over-rev it and cause damage to the motor. If the 300 is lower then no damage, but the 250 will never be able to run top speed. If they are the same then you are 'golden'. But in the normal operating range it should be fine for riding around and towing etc.

 

Thanks for the reply. The CDI box "looks" fine but word was that someone hooked up the battery backwards so I'm worried that it might be bad. There are no melted wires, though. I think the coil is probably the bad part. They are cheaper to replace so I'm going to try and get a new one of them but I have to get everything hooked back up and see what I get. The guy that gave the Cat to me is a good bike mechanic but isn't good with electrical and that is what I'm good at so I will clean all the wiring up and test for continuity all over and see what I can get.
Do you know if there are any fusible links in the harness? There are a couple of plugs that look like that's what they are but I'm not sure. Ijust pulled off the panels tonight and spend half an hour looking at all the plugs and it seems that it might be ok. There are 20 amp fuses in the fuse holder (factory supplied 10amp) and one of the fuses is a piece of 14 gauge wire so who knows what could have happened there. The key switch was broken so you can't use a key but it still turns fine. There are only two plugs that i can't seem to figure out where they go but maybe if I spend more time I will.

I just don't see why people abuse their machines so badly. This thing was supposedly running and then just quit. That's when they started messing with everything. The battery cable is literally two cables twisted together and taped. The fender that rests over that same cable has melted spots so I suspect that it grounded out, got hot and they had to change something. Mysteries all around.

Free 4 wheelers can be fun if they run but at least the engine in this thing seems perfect. Do anyone know how to find out the year model and where the numbers would be? I assume its a Suzuki 250 but am not sure exactly what year. All the parts lists only have 1999 and newer for it so I'll have to use those parts..

Thanks.

 

If you just are comparing part numbers, or just need to see what a particular thing looks like, try going to Ronnies.

The parts diagrams go back to 1997.

 

If it is a matter of hooking up a battery backwards, unlikely the CDI was damaged there is a protective fuse for such accidents. I know where it is on my machine but not on the 250, but I think if you follow the hot wire from the CDI or battery you will find it. It is encased and it is probably around a 30A fuse.
You can also look up parts etc here:
http://www.babbittsonline.com/...brand/3/ArcticCat.aspx