The side where the wires come out it looks like chunky epoxy or something like that.

 

so you have a running/working cdi with chunky looking epoxy that looks like it is melting out from the inside. I have worked on atv's for 12 years and I know that on some atv's and blown cdi might swell the plastic shell. so is it normal to see this epoxy chunks on these cdi's

 

I have a 98 warrior CDI with the same chunks they almost look like little crystal chunks. It works sometimes and then cuts out. If I shake it it doesn't sound like anything is loose inside.


98' Warrior

 

I would like to burn my warrior, if I didnt have so much money in it I would!! Im so frustrated with it I could take it to the yamaha shop, and I never take my stuff there!

 

<div class="FTQUOTE"><begin quote>Originally posted by: Raptor450

http://www.sandwizards.com/Service_Manuals/warrior.pdf Chapter 7.</end quote></div>

If you read the chapter on wiring and have a multi-meter to test the electrical components, it will save a lot of frustration. If you don't have the electrical tools to check things, you may want to just suck it up and get somebody else to look at it. Trying to diagnose an electrical part by shaking it and looking at "chunky epoxy" isn't going to cut it. I see why you are frustrated. Just guessing and replacing expensive parts and then still not fixing it sucks.

 

Im not shakeing and looking at epoxy, I could give a rats @$$ about epoxy, what Im getting at is Im looking for someone that has run in to this problem before. I have check all of the wires and switches grounds and could not find any problem, so I started with the most likely thing to go bad and that was the stator, then the relays, switches wireing harness, cdi box, coil, flywheel, you name it and I have two of them one new and one old. Im not new to working on atv's I have been blessed to be a jack of all trades but a master of one and electronics is not it. I understand how every thing has to work in order to make it run, but for some reason It wont, to be honest I want to put a ford dura spark ignition on it and be done with it but I really want it to be factory and right that way it might be worth a grand when I want to sell it. Has any one ever encountered this problem? Replaced the entire system and still no spark? Its like its cursed or something?

 

Its not cursed. Obviously something is hooked up wrong somewhere, there is a short, or one of your new parts is not functioning.

 

my cdi has the same texture on my 2001 warrior. it kinda looks like there are little gravels in the back. I have very little spark, it fires every time, but not enought juice to even ignite either.

 

i would try a new/used wire harness. they are like $150 ate Yamaha , but i would try eBay first.

 

I got a new harness from the yamaha shop for $125 but it still doesnt work...