I need help!! I took in a Arctic cat that was not running the owner had a friend replace the stator and flywheel (loose magnets) and said that a friend of his had also replaced the, CDI, Volt reg, coil, and plug. He said it started for a sec then died then never started again. After doing vast amounts of research I discovered that it had the wrong CDI box plugged into the harness (it said KDX400 on the CDI) it was popping the IGN fuse and had burned up the Diod in the fuse block. So I had the owner order a new CDI from Arctic Cat. After the wait for the correct CDI I installed the new one made sure all connections were correct and it sparked about 5 times then quit. Rechecked fuses, connections, downloaded a copy of the service manual that explained how to test the high voltage to the coil and It had 497vdc when the key is turned on and 275vdc when cranking. This is measured with the black lead of the dvom connected to the white/blue coil feed wire and the red dvom lead to ground. The service manual states that it should be 160 to 240 when cranking but doesn't say what to do if it is out of range. The resistance/ohms measurement on the pickup/trigger coil is 200.ohms. I have tried different coils and even tried the old CDI that was original with no different results. I have had the side cover off to inspect the Stator installation and have checked resistance on all of that. I have checked with the plug resistor off of the coil wire. The odd thing is if I remove the coil pos lead from the coil and intermittently touch the lead to the coil it will make the coil spark. New battery fully charged even tried to start with pull crank in case the diod in the start button was bad. I know there has to be one of you out there that knows what I am missing here and I am willing to be educated at this point. So, help if you can please.

 

Is stator the same brand as the flywheel[Denso or mushba] If not match brand it canbe electrical out of time? If no brand on stator and If you have old stator may want to count the number of bars that the windings are on to see if same amount also see if windings are the same size Just guess here, If stator and flywheel all OEM I still would research some to see if Arctic Cat [Suzuki] offer 2 different brands or stator and flywheel Normally all atvs have 2 chioces

 

Thank you for the reply.
The stator and flywheel were bought together and previously installed by the friend of this guy and I have had that apart to measure flywheel size and stator size and have also swapped the trigger coil out with one that measured the correct ohms. I always thought that the stator was only for charging the battery and the pickup coil or trigger coil was used to signal the cdi when to spark. There is a yellow wire and a white wire coming from the stator that connects to the CDI the ohms reading checks out okay but it doesn't produce any power when spinning engine with starter or pull crank. Should this have voltage when spinning?

 

Yes I think so let me look tomorrow when I get back to shop I think I have manual

 

Yes. If it is like the Suzuki LTA500F I just worked on, it should have both a trigger coil and a power coil in there. While the pickup coil
is supposed to put out something like .5V peak, the power coil is something like .7V peak. That may have been messed up or not
replaced in the earlier stator removal.

BTW, your coil primary peak voltage should be more like 150V or so.

Does your voltmeter have a record or peak function?

 

 

If you can't get at least a half volt pulse off the power coil in the stator, it needs attention. If someone was in there when
the last repairs were attempted, that is an alarm. I can't tell you how many times I have seen previous work causing
big problems.

High 400V range for coil input is too high, IMO.

 

I checked a wiring diagram for an AC 400: There are 2 coils in the stator that need to be checked. One is the trigger
coil (200 Ohms), and one is the power coil (0.1 Ohms). I do not know what the official AC output V is for those 2.

 

 

Here is a video of the unit running