The yellow and yellow red wires are the charging wires from the stator. The black wire from the cdi is the cdi kill wire.Pull it and see if you have spark. Cdi can short out internally because of the kill circuit wire. Coil should show a small resistance reading from the tab to ground. Still may have something to do with the connector you used instead of the right one.Plus don't over look checking out the left control emergency on/off switch and wiring along with the ignition switch and harness.

 

I checked the kill switch working as it should.
So I assume the yellow/red wires have nothing to do with my problem for now.

You say pull the black wire?
It goes to the coil with the with a white wire to a jack.
I am a little puzzled when you say pull it - sorry - do you mean disconnect it to the coil so only the white will go to coil?
Sorry for not understanding.

I also checked and have 12V going to CDI via red.
But cranked it and tested the black and white from cdi and no voltage coming out- not sure if that was proper thing to do.
Thanks Alot for your patience..

 

Also double checked my new connector for the stator wires that were cut, all have good continuity.

 

Sorry! Was thinking of the other models. Yes you have two wires leading to the coil on the updated ignition. You should have power to the cdi red wire as this is a dci ignition system instead of the old magneto triggered ignition systems such as the earlier Sportsman 500. Trying to measure current from the cdi is not an accurate way of testing the cdi.Manual actually doesn't have a test on it. You have to eliminate the stator and coil per the resistance specs. If in doubt about the cdi you have to replace it with a "known" good one to test. Easy for most shops,but not for the owner. On the coil check the coil tabs to red test lead and black to ground with the cdi wires removed. You should show a small resistance reading. If not it cold be a defective coil.

 

Here are some pics of the CDI, Etc.
What is the large jack that has a blank plug in it for? Winch?
Can you tell me where you meant to pull the black from CDI...
Also I do not have the large metal box with fins controller? Why.

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sorry trying to learn how to load pics.

 

I have 12+ volts to the CDI.
By tabs do you mean wires at the jack it's the brown jack with white and black wires, no red at coil.
There are CDI output tests in manual but talks about a Peak Reading Volt meter I may have to buy one.
I think with my Stator readings it may be good, just wondered how the volts get to coil.
Thanks a million OPT for your time on this.
More testing tomorrow....

 

[QUOTE=easygoin43;3233611]Here are some pics of the CDI, Etc.
What is the large jack that has a blank plug in it for? Winch?
Can you tell me where you meant to pull the black from CDI...
Also I do not have the large metal box with fins controller? Why.

That's the resistor module harness and plug. You wont have the finned module (ecm) just a regulator/rectifier as the ecms came out in the 2005 models. This was a work in progress as far as the 2004.5 model is concerned. Depending on manufacture date even the coil was changed twice. Items #15 and 16 replaced the Ducati coil pack #19. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Enter your 17 digit vin # located on the lower left frame here to actually see date of mfg and other info. Polaris Off Road Vehicles: Four Wheelers, RANGER RZR Side by Side ATVs and UTVs

 

I just found that site yesterday - However it does not show mfg. date just year- unless I a m missing something- it is a 2004.5 tho. SEE BELOW:
Vehicle Identification Number 4XACH68A14A060057
Model Year 2004
Model Number A04CH68AK
Model Description 2004.5 ATV, SPORTSMAN 700,GRN/BLK
Engine Serial Number 0000000014808
Purchased Date 12/31/2003
Warranty End Date 06/30/2004
Extended Warranty N
Dealer Name PERFORMANCE EAST, INC.

DO I still need to pull that black wire as you mentioned- if so can you clarify as to exactly you meant.
thanks

 

Since the black wire from the cdi is in a connector with the white wire,just snip the black wire and see if you then have spark. If that doesn't help you can always splice it back with a heat shrink connector and check for a other things that may be causing the loss of spark. All this is doing is just eliminating the black kill wire from the cdi. Other models you can do the same thing as it's not uncommon for the internal kill circuit of the cdi to short causing loss of spark. If it does have spark when you snip the wire,the cdi needs to be replaced or live with having to choke the engine down to kill it as some people I've seen do. One of the main problems is the 2004 manuals don't really address the 2004.5 model completely as you've seen on the different wiring colors and the 2005 model manuals are changed even more with the changing to the ecm modules,that incorporated the main circuit breaker,fan circuit breaker,charging system,etc.