I have a 200 grizzly 600 with no spark. I checked all wiring connections. The resistance on the coil, pick-up coil and stator is all good. All wiring is also good before and after the cdi. Could be the cdi box since the back of the box is very rough and bumpy and they are usually pretty smooth.

New items in the last 3 months are battery, coil and stator and pick up coil.

Is there a way to check that the new stator and pick up coil are working other than just checking resistance?

I'm getting sick of wiring!

 

bump

 

Have you tried a new spark plug?Ive seen this so many times. A good flooding will coat a plug so bad, that even after it dries out, the resistance is so high, it wont jump a spark.That would be the first thing to eleminate.
Have you tried to bypass the kill switch?
Hows the battery? If you use the rope pull starter, will you get a spark then? Sometimes the battery will still spin the starter, but not have enough juice leftover to spark the plug.
Its posible that the cdi box went bad, but thats the last thing to change out. Lets eliminate all the cheaper posiblities first.
Have you got a service manual? There is a troubleshooting guide in there, for no spark, and itll step you thru the logical progression of things to eleminate.

 

Thanks for the response.

I do have a service manual and have gone through the troubleshooting for the electrical system.

I tried several plugs just to be sure. I haven't bypassed the kill switch but have tested the switch and its working properly. I have also tried using the pull starter incase the starter was drawing too much. The battery died this summer and I limped it along til about 6 weeks ago and bought a new one and its fully charged.

On a side note when the old battery was weak my boss was out hunting and a stick came up and tore off his fuel line so he called me to come rescue him. When I went to start mine the battery was low so being in a hurry I stuck the charger on it and used the 50 amp boost to start it (now in hindsight that probably was a dumb thing to do) and after that I had only run it a couple times for maybe 15 minutes since after I put the new battery in I was having a hard time starting it. At that time I had weak spark and checked the pick up coil and the resistance was very low but it would start. Finally one day it wouldn't start so I checked the pick up coil again and it had no resistance so I changed the stator and pick up coil combo since I got a new one for only $80 on eBay. And Thats where I am now, the new atator and pick up have the right resistance but I have had no spark since I changed it. I find it hard to believe the pick up and CDI could both go out at the same time unless the 50 amp boost from the charger screwed something up since the back of of the CDI looks pretty rough and lumpy.

 

Sounds like you got a good handle on things. Do the fuses look good? There might be an ignition fuse.
The 50 amp booster didnt hurt anything. The internal resistance of the starter only allows so much draw, no matter how much is available. Its only if the charger put out more than 15 volts, that it could hurt anything.
Was there a procedure for setting the gap, on the pickup coil? Or is it a fixed distance?
Id also recheck all the connections, especially at the stator, to make sure the pins touch, and they are clean and dry inside.

 

<div class="FTQUOTE"><begin quote>Originally posted by: hondabuster

Sounds like you got a good handle on things.</end quote></div>


I'm tryin' to convince myself of that.....I absolutely hate electrical problems and in the last 2 weeks I fought with the snowblower which had a shorted wire, the trailer lighting taillight converter went to hell on my truck and now this......I'm beyond stressed....lol

Anyways...the fuses are good(I even checked them with the test light even though I could see they were good) The pick up coil gap is fixed other than the slight play between the bolts and the mounting holes. I also by-passed the kill switch last night with no luck but then I thought the starter probably would work if the switch was grounded out but maybe I'm wrong.

I'm gonna go through everything again incase I'm just overlooking something stupid.

Tonight I'm taking off to destress.....I hope.

Thanks for your helpful ideas.