I'm having the exact same issue with my 06 manual 4x4. I already replaced the flywheel with the new designed one and put in a new stator/trigger coil. I've tried all of the same things you have done as well. I'm down to the voltage reg or cdi being bad. I put a spark tester on and ran it, the ignition is breaking up when it falls flat and spits and sputters. Ill keep trying and let me know if you get it figured out. Ill do the same.

 

I surely will let everyone know when I get it figured out... I've been fairly busy with work but I have the next couple days off and I'm going to check the few things that have been suggested to check and see where I end up. I believe that the VR is working properly because I have around 14.5v when it's running. But I'm going to check the timing and hopefully the compression on a motor with about 2k miles on it... Otherwise I think it's going to be a cdi. I just have to see if I can find one that isn't $400+

 

Hi Jm, Check your email.

 

Well, mine seems to be different than what was described earlier... I have to take the tank off and the top of the head off(valve cover) to get to any of this. It looks to be a new gasket(or RTV) when I do this but I want to be sure of what I'll be lining any marks up with once I take that cover off... And the owner of this 4wheeler still hasn't gotten a comp tester yet so I really haven't done much to it today besides start to pull the tank and look at it. If anyone knows what I will be lining up I would be appreciative of that information... Thanks

 

ok so I got a manual for this thing and from what I can tell I'm getting no power from my pickup coil. Would it even run if this was the case? all I have is a digital meter so I can't tell if maybe the peak voltage is coming on and going back on so fast that my meter won't show it... Other than that everything is in spec according to the manual. Anybody know anything about these? could it be a case of broken magnets? From what I've seen I'm not all that interested in pulling that side cover because of all the gears and stuff in there... But I will if that's what needs to be done.

 

Compression is 120... the pickup coil can't be bad because it still runs.... is that enough compression to run? The manual says 145 new but gives no specs on variance.... anybody?

 

Yes It sure..But could give an issue in running on hard accel. Have you checked the value clearance yet? If not you could have an .001 or so to tight intake value.Since the carb has an cv type slide in it.and this is lifted by compression so It couldbe an tight intake value..25 or 30 pounds could make an big differents.I alway check compression and ignition before I do any carb work...If compression is off to other componenets will not work correctlly.IMO I would go ahead an check vale clearance.

 

No i didn't get around to checking the valve clearance today... I took the mag side cover off and rechecked everything in there, It looks like it's either been replaced or they put the upgraded magneto on it with the stainless inner liner on it over the magnets. It'll probably be next weekend before I can get to checking the valves... But I'll let you know when I do and also recheck the compression if either one of them is out of spec. Thanks again

 

Ok thanks......Good Luck.....

 

Does it have an aftermarket flywheel on it? Should be denso or misuba. I believe..If you can see an name on flywheel let us know please...Sometimes an aftermarket flywheel has got to have stator and cdi to match are the engine ignition could be out of time...Sometimes an flywheel brands have magnets different lenght and spaced out different then other brands SO Its real important that ALL ignition is made to match up each other when flywheel has been change..Also if you can see if flywheel and stator has the same name or emblem on them... Its that important. It got my attenion whaen you said flywheel looked new....Thanks.