OK the history. I have an 06 LE Pred. I put a pipe and K$N on it right after I got it. It sat for several months after a car accident I had. When I was healed up I put on new Custom Axis shocks and went riding. It rode fine for a while then started popping and sputtering in the hills like it was a fouled plug. I had jetted it a little richer so I figured that was it. I revved it up to try and clean up the plug. We stopped and it wouldn't start back up. No lights, no clich , no nothing..dead battery. I put in a new battery and went for a ride. It was sputtering and popping again, but mainly half throttle and above when it was being ridden, no so much if I had it in neutral and revved it. I rejetted the carb to Rath specs, and tried again. it revved fine with no load, then when riding it started acting up again about half throttle. It lost power like before and was almost like it was hitting a rev limiter or a stumble point early. The carb is clean and properly jetted. The air filter is clean and secure. air way is not obstructed or dirty. valve clearance is dead on. all equipment is the same as before the problem started. I am going to drain all the gas, clean out the tank and see if that helps, but I've run a good amount of gas through it so it shouldn't be that. Does this sound like an electrical problem to you guys ? I don't know if the dead battery could have done something, or if maybe the coil or CDI have gone bad. It doesn't have an excessive amount of hours or anything and compression is still great. I'm banging my head here. I dont want to go pay $75 / hour to have them tell me they don't know or to replace what I think it is now. I was considering replacing the CDi with a Procom, and the regulator, and the coil.... what do you guys think ? have any of you had similar problems ?
also I know years ago the procom wasn't that good of a unit, but hear they have changed a lot and several people have had good results with their products. I am not racing so don't want to spend for the vortex or dyna, is procom any good or is there another brand I should consider ?
I really appreciate your time for reading and any help you can offer.
Thanks,
Cain

 

We are having this exact same problem. not sure what the heck it is. we have done everything but change the carb and fuel pump. We did the the CDI but it did not do anything. NEED help ASAP Please

 

does the lobes on the cam look alright?
is the timing set right ?

 

Yes and Yes

 

could be a short in the wiring
ground wire loose or corroded
magneto dirty or corroded
plug wire loose,dirty,or corroded
inside the ignition switch dirty
the bad thing is it will take forever to find the .05 part to fix it.i hate to work on something with that kind of problem.it's not a major problem that's easy to figure out.it's one of those little things that could be a million things.