Let me start by saying i am a small engine/atv/utv mechanic with 20 years experience. but once in a while something stumps me and this time im asking for help. I had a customer bring me a 06 raptor 80 with no spark, they also brought me a new stator,cdi box and coil that they purchased. I installed everything and i have weak spark now. I cleaned cables,cleaned surfaces where coil and rectifier mount to assure good ground,i made ground cable from motor to frame. I have tested new parts for correct resistance and continuity,i checked off/on switch. no matter what i try i still get constant spark but very weak (not enough to fire under compression) im using a spark tester and ive tried a new plug also. does anyone have any ideas as far as what im missing here. i have replaced many stators,cdi's,coils, etc and never had one get the best of me like this is trying to do. any input will be greatly appreciated

 

You tested ohms, but not voltage...correct? I'd start at the stator and work to the plug ensuring acceptable voltage...I'd guess one of the new parts is faulty or the stator/flywheel are just not putting out enough juice...IMHO...

 

Hello from NY. This is way to coincidental, Been working on bikes ATV's, UTVs and sleds since 1987 and I am now stumped as well. I am actually having the same problem with an 05 Raptor 80. Everything has tested good and continue to have a weak spark. I have been inside and out of this lil' machine. Let you know the outcome if and when I find the issue