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I'm having a problem getting a CDI unit that works. The parts list calls for a 4XE-85540-00-00 CDI unit. The one currently on the ATV works but there seems to be a problem with the spark advance curve. It will idle fine an rev. to about 1.5K then starts bogging down sputtering, popping and basically running poorly. If you can get it above 2200 RPM it runs better. I have ordered and returned about 5 replacement modules that will not work at all. The unit currently on the bike has no part numbers or identification other than a Mitisibuchi logo. I am wondering if anyone else has experienced similar problems with replacement CDI's and if so what is the fix? So far I have not found a replacement CDI that will supply an pulse to the Ignition coil.
By Brent Mason
I have been trying to get my Griz600 running right for 3 weeks ! Grandsons used it and it quit running , no spark ! New stator etc and started but ran terrible ! Found a burnt capacitor on cdi . Installed used cdi and burnt it also but ran same as other cdi . Came to conclusion wire harness had short so stripped it and found some bad spots fixed and another cdi ran terrible again ! Bought another harness and same rough running ! Checked spark timing with light (put tdc mark on case and on pull start hub) and when it starts timing right on but will jump 25+° retard ! When timing is on tdc marks it has no power ! The stator is new but I am wondering if the pickup coil is triggering incorrectly ? Also had top end apart when I first started having trouble and although rings were good I installed new rings . Also new timing chain and check the valves , they were good also . It kind of seems to boil down to the last stator I installed new ? I have done trouble shooting on quite a few cars , trucks , dirt bikes and ATVs but this is frustrating me ! Just wondering if anyone has any ideas ? Carb was new last yr and I checked it ! I
By Brent Mason
IMG_4272.MOV Originally had my griz600 stop running and then wouldn’t start ! After testing all coils , valve lash , compression (115psi) and all tested ok I bought a used cdi . After cdi install it still wouldn’t start (no spark) ! So even though the stator , pulse/trigger and charge coils check within good range I decided to switch the stator etc ! It started but It is very unresponsive on throttle and acts like it is running in 2 Different spark timing ! With slight throttle it will take off good but instantly go into a very different running mode with no power like timing very retarded but it will switch back to running good for short period then bad again ! Since I replaced the stator and it started I then decided to install the cdi I replaced and it did the same thing ! Also I noticed the Used cdi I Took off had a capacitor that had swelled and extruded from the back of the cdi . I had always heard and I believed that when these CDIs go bad they machine will quit and will not run . Is that true ? I also checked the cam/valve timing and its ok ! Checked with timing light and it does fluctuate on idle ! I am thinking I have 2 bad CDIs . I also switched the trigger Coil wires and would not start then . Man , this thing ran good before and I am confused ! Video below may help !
hi all first post just found forum and the manuals / wiring diagram BIG THANK YOU
im struggling to find the vin number on my frame? I m told left side of frame , lower, nr. in front of the gear pedal ?? haven't found it yet , is it numbers stamped on the frame or a commission plate ??
main prob. no spark no power to coil , off to study the wiring info I've just found
thanks again. tom
Hey there all,
First off thanks for the board. My Bayou 220 has survived 3 teenagers and is on its 4th now. Up until recently it has been a virtual tank....until I decided to fix it;)
Noticed some smoking from the engine block (not exhaust) so figured it was time for a quick top end rebuild. Now that I have it all back together, it fails to start. I've pulled the starter rope until my arm is tired.
So I will be as detailed as possible and hopefully get some help.
-New Head gasket
-New Valve seals
-New piston (standard)
-New rings (standard)
-All new seals
-Cleaned up head and valves (didn't do any resurfacing, as it all cleaned up pretty easy)
-All torqued to spec
-Piston ring gaps all checked out
-Valve clearances (Intake: .18mm, Exhaust .20mm). Not too tight, not too loose.
-Engine IS making decent compression
-DO have spark
-Will fire for a split second if I drop some gas in the spark plug hole and pull start. Will NOT from carb and or intake valve.
So I followed the guide of: TDC
-Flywheel aligns on the “T” mark on the engine site hole
-Cam gear mark aligned with the cover mark
Seeing as this is my first time doing a top end rebuild on an ATV. Here are my questions and concerns:
-I didn't realize (dummy me) that there are 2 TDC's. 1- Compression, 1-Exhaust.
How do I know if I'm on the right one?
-Does the cam need to be aligned a certain way when put back in? I just aligned the cam gear dimple with the cam and put it in. No alignment.
Thanks ahead of time. I feel like I'm 90% there, but I'm missing an important step for completion.
So, I got this 07' Polaris Outlaw 90 in the shop to rebuild top end and transmission. Replaced all bearings and gears in the transmission. Replaced cylinder and piston with brand new parts. Put the engine back on the frame and fired it up. Started great, but had a taping sound in the lower crank case. pulled the flywheel cover off and found the flywheel was wobbling and hitting the stator. I then replaced the stator and flywheel with brand new parts. Timing is all set on the timing marks now, but when I turn it over it kicks back when it fires and ends up stripping the starter idler gear. I've replaced the starter gear once already and now have to replace it again. Is it possible that the timing marks on the flywheel are off or maybe this flywheel is not for this exact model? Thinking of advancing the timing to try it, but don't want to keep going through idler gears.
By Susan Makowski-DeGraw
My quad runs, it starts up runs for about 10 minutes and then it dies if you let it sit for 10 minutes it’ll start back up ride for another 10 minutes and then die again, trying to figure out why it keeps stalling
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