Hi Guys,
I've been looking for some help on my 230E and finally I think I found the right forum...I didn't think anyone had these anymore. I had a problem a while back where the chain popped and cracked the piece behind the front sprocket. That piece, in turn, lunged forward and cut through one of the stator wires. I took the side case off and soldered the wires back together and insulated them with 200C fiberglass insulation from work. Then I taped it all up with super33+ electrical tape. I thought it would hold but now I'm not sure. In March my brother rode the quad for the first time since I fixed the stator wires and everything was going fine but then it just died and would not start. We towed it home and I fooled around with it for a few months off and on. I finally found out that by disconnecting the ground to the CDI, the quad would spark and run fine. The spark is not the blue I have read about but regardless it runs. So, I wired a switch for the CDI ground for the time being until I can figure it out. I have posted this question on other forums to no avail. I have tried a different CDI and coil but the only thing that will allow it to start is disconnecting the ground so I believe the ignition system, at least the CDI and coil, are fine or it would not run at all. I came to the conclusion yesterday that maybe one of the stator wires is shorted so that it is acting as the ground so that when I disconnect the ground to the CDI it is basically operating in reverse. I tested the coils and they are all within spec so at first I thought what I fixed was fine. But, if one was shorted to the case, the coils may still be within spec and the short would never show up. I guess, now as I write this, that I could test each of the coil wires to ground to see if there is a short. Anyway, I just thought maybe someone here has had a similar problem and can shine some light on the subject. By the way...I also own a grizzly that I let my brother and his wife ride yesterday and the 230E went through all the 2-3ft deep puddles that my grizzly and the three Polarises we ride with did. I have to say, the thing still impresses me. Thanks!