If this wire does go to ground via the CDI box. Can it be disconnected? If so disconnect and ground it yourself. If not. Decide if its worth it to cut the wire and ground it yourself. If it is the CDI, it would be a much easier and cheaper fix.

 

I am having the same problem you had, what was the fix for? Any help would be great.

 

I believe there is a sensor switch in the reverse lever that is a common problem and will disable your starter on occasion. But you gotta start in the beginning and go through the stuff mentioned here also. the same symptoms can be caused by numerous things on a warrior.

in the original posters remarks he had problems with the starter cut off relay. Since the ground on the lead from the CDI activates the relay something else tells the CDI to ground that lead. Alot of times its safety stuff, like clutch pulled in switch, reverse lever sensor switch problems. If everything checks out the CDI will let you start the quad, thus - "cut off relay"

 

I was hooking up my kill switch and did it wrong, basically I grounded the orange wire lead that goes into the coil. Can anyone tell what that would burn up. I have done a lot of checking and yes iI did check the fuse.
At the wire going into the coil I only get about 1/2 of a volt when cranking. I also checked it with a test light and got nothing. Any suggestions why my coil in wire isnt getting power?

 

I think that is the right wire for hooking up a kill switch, which I believe you do at the coil.

Check for "AC" voltage on that lead. I believe it is DC but may be too fast for your meter or your light has too much impedance.

 

AC shows about 250 mV. I checked voltage out of the voltage regulator and it reads between 8 and 11 volts when cranking so I am pretty sure the stator is putting out. All of my switches seam to be a little off by what the book says the resistance should be but I cant see how grounding the coil could burn up everything. I also checked for hot or warm wires immediatly afterwords and found none.

 

every thing is back to stock configuration minus that damn kill switch which is totally unhooked

 

well i cant really remember, since this all happend like a year ago. But the problem was definatly the CDI. I was trying to fool myself that it wasnt, so i bought new relays and stuff but they didnt do a thing. So finally i got a cdi for like $330 from some online store (as opposed to the $400+ from a dealer) and just replaced the cdi. It has worked fine since then.

Now i remember i did something kind of insignificant with the electrical system, that i couldnt see how it would burn the cdi out, but it did. For the life of me i cant even remember what it was.