92' trail boss 250 no spark. original owner must have installed optional cooling fan kit. anyway i found spark plug hi-tension lead cut in half from fan blade. i put a new plug wire on and still no spark. i have a clymer manual on this machine, and making test light cks. i have no power to the coil and i have a signal from the stator to the cdi module but no signal from cdi to coil. so i think the cdi is bad, but i'm not sure i'm testing it correctly. any suggestions.

 

Pull the black wire from the cdi to eliminate the kill circuit,if has fire then left control switch could be suspect(corrosion,etc).Also check that all grounds are tight at coil base If still no fire, then stator resistance check is your best bet as any power to cdi is not an accurate way of testing. Tests on cdi units are to replace with a known good one! Cdi units and coils rarely go out,usually pulser coil at stator or stator charge coil. Dont know about clymer,but should have schematic page with stator resistance wire checks. OPT

 

ok, i had to pull the coil to replace the hi-tension lead. i do have a schematic in this manual but volt/ohms values are pretty broad so i'm pretty much doing continuety and test light cks. this machine was obviously parked in a barn. i'll start from scratch and ck all associated grounds and component grounds, alot of dirt and rust. my nephew was riding and it died. so when i went to ck. a no start condition i found the cut plug wire. the fan may have cut more wires. i may have also disterbed a ground. i just wondered if when the plug wire got cut it shorted the stator pulse trigger or the cdi box. but thanks for reminding me to keep it simple. signals, grounds, shorts, etc. i'll tear back into it tomorrow.

 

i pulled the black wire and it starts but obviously will not shut off now that i pulled that wire. so i munipulated the run/stop switch while touching the black wire to it's connection and it dies. so i will run continuety cks. on switch, schematic shows black wire also goes to ign. switch and reverse limiter. i found a two wire switch taped in the closed position, taped up behind head lamp/hood area. when operating the swich it acts as an overide to the rev. limiter. switch wires go straight to fuse block and are black and b/pl. i don't know why some one hid this switch. anyway thanks for leading me in the right direction. i got some switches to ck. now.

 

Sounds like you are a pretty good electrical trouble shooter! Good luck OPT