what size fuse is it? at least a 7amp, right?

 

Yes it is a 7 amp fuse.

 

Does the voltage go from the coil to the stator then to the regulator or from the coil to the regulator then to the stator? I took off the plastic cover to the fan, flywheel, and the stator...there is a little rust on the flywheel. I didn't take the fan off or mess with any of that - yet! Is there any way to check the stator without the regulator connected? Thanks

 

I got it cranked last night, but it wouldn't idle. I cleaned the carburetor and now I am not getting enough power even jumping it off to turn the motor. It isn't spinning fast enough to start it up! I have to leave the regulator off to do anything with it still.

 

i wouldn't think it would be the cdi box. what happens when you turn it on without the cdi hooked up?
did you double check to see that you have the proper cdi box? (by part number and model)
who manufactured the box?

i haven't heard of a cdi actually causing a fire

 

I have great spark and compression, it just seems like the starter isn't spinning fast enough to turn it over. With the battery getting 12v and without the regulator connected. It cranked up and ran last night but I had to give it gas to keep it running, so today I cleaned the carburetor. I can hear the solenoid relay click so I know it is working, and the starter spins - it just doesn't turn it over.... what could be wrong?

 

Defective battery with low cranking amps?
Stator not putting out enough power or rectifier

 

Tried 2 batteries, same outcome... regulator/rectifier isn't even hooked to the harness because it pops the fuse as soon as I connect it, so I figure I can run it and just charger the battery when I get done (its just for the kids to ride around the yard). If it was the stator would I have spark, it cranked up a few times but wouldn't idle so I pushed the gas to keep it from dying and then it just quit turning over.

 

i wished i could put my hands on this quad to help you out. i'm almost to the point now to see what a new wiring harness would cost from arctic cat. something is amiss within the loom. are there any atv boneyards around your area? a loom swap wouldn't take long to perform.

 

Check your groung wired throught the harness. Make sure they are all tight.