Need some feedback here. I picked this machine up with PO saying no spark. I have tried new stator, CDI, and coil. The stator ohms 231 w/r to w/g and .1 red to blue. The coil is .8 primary and 2.53 secondary. I have 12 to the CDI with ign on and the wires from stator to CDI have good continuity. This model only has 12v on or off for ign/kill source. Still no spark?

 

That is one weird ignition set up. A 12v feed indicates DC ignition but four wires from stator to CDI plus a kill wire, indicates AC ignition. Seeing as the kill wire goes to earth with ignition off, I would be surprised if it should have 12v on it. Check that the 12v pos is coming from the CDI kill pin, as the black/white should be neg or open circuit from the ignition switch depending on position. May be worth checking AC voltages from those stator coils, though I've no idea what they should be.

Just rechecked the incredibly complex wiring diagram, and it looks like the pos wire to CDI (blue/white) is only "live" when the starter button is pressed, so that would make it a device for increasing spark when starting, on an otherwise standard AC ignition set up.

 

The system seems to be 12v dc only. I don't see any ground used for kill switch. I added a new ground to the engine and checked the wires from the stator to the CDI and the large orange wire from CDI to coil. I am wondering if it could be a bad flywheel? I have two of everything and still no spark. So I am missing something. Maybe something obvious that I just can't see yet.

 

According to the diagram the ignition switch is the standard two separate switches, one switches a pos feed from battery on, the other switches earth (black) to kill wire (black/white) off when you put the key into the on position. Kill switch does the same on a separate spur. No way is it DC, as I wrote above pos only goes to the CDI when starter is engaged via the blue/white, which also goes to starter solenoid.

 

On the 2000 and up Bear Tracker the ignition switch is only 2 wires (red, brown) and the handle bar kill switch is only the same 2 wire. The first ignition switch they sent me was a 4 wire and it was wrong. The best I can tell there is no ground used to "kill" the engine.

 

OK, my diagram is 1999 so must not be correct for the 2002 model but four wires from stator to CDI make it an AC system. Honda went in for weird AC/DC CDIs on some models but I doubt if Yamaha did. Put the wiring diagram up on here if you have it, that would be the only way to make sense of your set up.

 

This should be from a 2001.

 

Right, so it is a "weird AC/DC CDI," even stranger than the Honda one, so the black/red should be pos 12v from the ignition switch. Not sure when the model was discontinued, but that could be a fairly short production run CDI and stator, if you got the wrong ignition switch, did you get the right CDI and stator for a 2002 model? The CDI must be different to the earlier, earth to kill CDI and the stator may be different too.

 

I have tried 2 CDI's and 3 coils, I am stumped!

 

I am not that well up on Yams. The local dealer was good and well liked so owners tended to go there rather than our "independent" ATV shop. If your wires to CDI plug test out right by the manual it has to be a CDI problem but I would try checking AC output from those two stator coils when spun on starter, and that you are getting power between the red/black and black with an incandescent test lamp, you sometimes get volts showing on a meter with no power backing it up.