Can anybody give me an idea what may be the cause of no spark. I have replaced stator,trigger,cdi box and coil. The strange thing to me is if you unplug the coil power wire turn the key on then plug the coil power wire back in you get one spark out of plug. Also with just turning the key switch to on reading the power to the coil shows like 300 volts without even cranking the engine, but when you crank the engine you still don't get a spark. I did see where Suzuki recall some 2003's for a broken ground wire but not 2004's. I have searched the web for answers but none seem to solve the problem. Magnets seem ok.

 

I had 4 of these atvs the other day were the magnets came unglued an rotated an causing ignition not to fire had to replace flywheel with the new upgrade flywheel...may want go back into left case cover an look at magnets location see if they have moved.I also had one on them 4 atvs that would fire the first rotation..magnets was moving

 

If you have the original flywheel it's the magnets. Get the correct flywheel puller.

 

The magnets are intact and not loose. Are you saying they still may have moved on the fly wheel ? How can I tell if they have moved?
This thing has just about got the best of me and I am about to make a boat anchor!

 

I had a Vinson that wasn't charging due to a failed stator, it ran OK, in fact the owner needed it for lambing time and got through by having two batteries and changing the battery when the starter slowed. When he could do without it, we sent the stator off for rewind. When it came back the bike wouldn't run. Tried everything, finally fitting a new Suzuki stator, it worked, the re-winders must have got it wrong. So was your replacement stator a genuine Suzuki one?

I'm a bit puzzled by papa hog scoot's answer, I have just put an Eiger back together after a "loose" magnet, it had had hit the stator, smashed the rest of the magnets and formed a magnetic dust that was all over the alternator/gear case. I can't see any way a loose magnet would just sit there without doing a lot of damage.

 

The magnets can still be intact but moved, that will cause a no start. Look for where the glue is and see if you can slide the magnets with your fingers.

 

I have a brand new flywheel with the internal magnets and puller for sale, $250 you pay shipping.