Hi, I've got a 2003 Kodiak 400 I've owned since new. It's currently got < 500 miles on it but has sat in my shop for about 13 years. Everything is bone stock on this Kodiak. Original tires still hold air. Last time I drove it, it seemed to be cutting out and the red reverse light would pop on briefly each time it did that. So I parked it thinking I'd get it looked at and just never got around to it.

I hadn't planned to leave it sit, so needless to say I have already had to go through the whole fuel system, replacing all but the fuel tank. I expected to have to do this. I didn't expect a no spark issue.

Knowing I needed it anyway I already have a new battery. When I started looking things over after discovering no spark, I did discover a ground wire that runs from the ignition coil mount to a bracket near the rear of the bike where the negative battery cable is also grounded. It had been burn to a crisp and had actually broken. I've replaced this ground wire, as well as a few that tied into it that looked bad. I've also replaced a few wires in the harness that had their insulation damaged by the heat. Since this came from the ignition coil I didn't trust it so purchased a new one which came with plug wire and boot. I also installed a new plug. Still no spark.

At this point, I did a bunch of searching the internet, downloaded the repair manual, etc. Pulled out the multimeter and checked for continuity on at least most of the wires in the harness. New ignition coil seemed in spec. All the fuses looked good. The pickup coil in the stator assembly seemed ok, but the rotor rotation direction sensing coil seemed iffy. That may have been my meter just not having enough granularity for very small ohm values. Any case, I replaced the stator assembly with a NOS assembly. My starter kill switch seems ok in that when off, the starter doesn't even turn over.

After this, I still have no spark. Correction, when I put the key into the 'on' position I get a single spark about a second later but none when I press the starter button.

So, I haven't found an inexpensive replacement for the CDI but that's about the last thing I know to do. I'm hoping there are some clues here, like why would that ground wire burn up so badly in the first place? I suspect this is what caused the symptoms that led to me parking it. Is that likely to have damaged a part I haven't looked at? Is it normal to get a spark when just turning the key to 'on'? Basically looking for suggestions on what to check next.

Thanks in advance for any help. --Rick

 

And a related question. Anybody know why the CDI module for the 2003 Kodiak 400 is so much more expensive than other years? I can find earlier and later model CDI boxes for less than $100. For 2003, they are harder to find and cost $350 or higher.

 

"Anybody know why the CDI module for the 2003 Kodiak 400 is so much more expensive than other years?"
Yamaha can charge what they like for parts if no aftermarket CDI is available, and manufacturers route other things through the CDI so that they are not worth aftermarket makers replicating them, so you have to pay Yamaha prices.

The burnt earth wire must have taken all the earthing load from the battery, so other earths from engine to frame, to battery, are suspect. If the CDI lost it's earth it may well have burnt out, as the one thing most likely to cook a CDI is no earth to it. However, get the earths sorted and you may get the spark back.

 

Thanks merryman for your response. I think that the CDI is a 1 year only part for 2003 so I expect that's why it is so much more expensive than other years. I'll spend some time going back over my ground connections and wiring.