My CDI is on order.. and I am not even sure that is the problem, it's just an educated guess since the stator checks out good on the voltmeter.

The four wheeler will fairly consistently start when cold, run for about 5 minutes, then die. As soon as it heats up it loses spark. Great spark when cold, but as soon as it gets warm, ZERO spark.

Any idea what would cause a no spark condition once it heats up?
I guessed CDI, but we will see if I am right or wrong. Sure hope I didnt waste money.

 

That's one of those things that's tough to diagnose over the internet, or without a service manual.

Hopefully you are on the right track.

 

did the cdi fix your problem?

 

I can think of a couple of things to try.
When you put on the new spark plug boot...did you lop off about 1/4 inch of the spark plug wire, and then cram the barb into it?
Its most likely not the cdi. On those older hondas, its common for the stator to be cracked, or rusty. If its cracked, itll run fine cold, and as soon as it heats up, the crack turns into a gap, and the magnitism , and spark almost disapear.
If its rusty, on the magnet and pick up coil area, shine them up.

 

CDI did not fix the problem, it's the exciter coil on the stator.
Anyone want to buy a brand new TRX350D CDI for ~$100? [img]i/expressions/face-icon-small-smile.gif[/img]

PS. Put the new NGK plug boot on a new coil. The volt meter tests shows the exciter coil is bad now. It's intermittant, which made it tough to diagnose and made me think it was the CDI. I'm sure when I change out the stator it will run fine.

 

Those can be a bugger to track down. At least it sounds like you've got it nailed down now.