Hey guys, I've got a 2004 warrior that has some issues. It typically fires right up when cold but after doing some trail riding for about a half hour it will start backfiring and then die on me due to it losing spark. The spark always seems to come back after waiting for like 10 minutes and then it fires right up. When it dies on the trail it always has bump started for me. Maybe this was just due to the the time it took to hook a tow rope up to my buddies machine. I figured these problems were due to a bad spark plug but I replaced it and its still having issues. Now, I've replaced the coil and stator. After doing that this weekend it fired right up and ran fine. For whatever reason I all of a sudden lost spark when going to fire it up this evening. It started not 5 minutes before it lost spark! I'm so frustrated right now and don't know what to check next. Any suggestions would be greatly appreciated!

 

Check out all the ignition circuit wiring, including the key switch. Check the bike isn't overcharging when it does run, by putting a voltmeter across the battery, over 15v and you have a faulty voltage regulator. If nothing else seems to be wrong, it looks like you have a faulty CDI.