Oh I see. So, here is the specs I got today. Stator was reading 241. Pickup coil was 107. coil tab to ground was 1.2. Secondary coil was 6.5K. Everything seemed to be reading high.

When I grabbed the coil wire, I noticed some black tape around the cap....undid the tape and the cap fell off. It was just shoved in the cap. I dont know if that would cause issues but maybe. Let me know what you think of the readings off the stator. Thanks!!

 

Get a new cap..This may be the problem if it happened to be shorting to the the cylinder head. Stator and coil readings are within the +/- 20% range allowed. On the meter ground the black and red leads together. May show some resistance that you can deduct from higher than normal 1.2 reading on the coil itself.https://www.google.com/aclk?sa=l&ai=...Hb_KDywQwjwIbQ

 

Just curious, the kit that the local mechanic got me looked like a cheap knockoff. The needle jet was wrong, jetting wrong. Only thing I could use was the gasket and needle and seat. Now, the needle was all metal instead of the rubber tipped kind that was oem. Do you think this would affect anything?
I did order in a new cap. It didnt look like it had a good connection at all!

 

I'm not getting any voltage from that cdi wire? Crank it over and nothing. Weird. Should be showing 20vdc?

 

I'm getting 90 volts now.....this thing is like a can of worms. I'm sorry I opened it

 

Some replacement kit needles don't have the rubber tip. The best oem type replacement carb kits around are Shindy.94-95 POLARIS SPORTSMAN 400L 4x4 SHINDY K&L PRO CARBURETOR REBUILD KIT 18-0397 Use only NGK plug caps.

 

Is 90dcv low? Should I be getting a new cdi? I do have a meter that will read peak voltage.

 

I wouldn't just throw parts at it yet.Get a new plug cap,recheck the carb,get the Shindy kit if need be and go from there. Also pull the black kill wire from the cdi after you get the new cap if it still cuts out and see if that helps. If it does then possibly a cdi could be breaking down.

 

Quick update, Got the cap and carb kit. Seems to be much better. Gonna take it out and see how it does. Thanks for the help!!

 

Hopefully the simple things like the cap solve the problem.