KLF220A no spark. I’m starting to lose my mind with it

[KW900A]

Hey all, new member, I just joined here hoping I can find some help, I’m always happy to help others but this time I’m at a complete loss. I’ll try to explain all this as best I can.

I got this 94 220 Bayou doing some trading, the guy said it had quit running, and they couldn’t figure out what was up so he robbed some parts for another one and this one just sat in his shed. So it has not run in years. It was missing the flywheel rotor with the ring gear. I replaced the stator. The factory pickup ohms out to spec, generates ac current (.6 vac), I have an Amazon and a used oem cdi, the original oem smoked when I hooked up the battery, safety relay and starter relay are new. Neutral safety is working. It will crank with the button. But nothing I have done will get this this to excite the coil. I have an oem and Amazon coil. Neither really ohm within the spec but I’m tired of thinking I’ve found the problem and buying another part, so I’ve just been checking for a pulse at the green wire to the coil. I’ve ohmed the wires, checked voltages, used jumpers to get grounds, and I can’t seem to come up with anything. I have been doing electrical troubleshooting for years but this thing has worn my brain out. I cannot figure out what I am missing. Sorry I know this is long winded but I have spent hours with this and am just about at a loss, I’m sure it’ll be simple but I’m at my wits end… thanks in advance

[Gwbarm]

You are very knowledgeable and have checked everything and everything comes up good. The pickup coil puts out voltage and has the correct OHM specs. It concerns me that the OEM CDI smoked when you hooked up the battery, that tells me that either the CDI is internally shorted or it is not the correct one for the Quad. I dont trust aftermarket CDIs they can be hit or miss, i generally read the reviews some say they are perfect and other say they dont work at all. I would look in that direction, everything else seems to be working correctly. The only thing i might add it to make sure you have 12 to CDI and a good ground, check continuity from the wire to the coil, maybe feed 12 directly to coil and see if it actually creates sparks, i say this because i have had them OHM out correctly and not spark and it gererally turns out to be cap or wire. Im sure you have probably checked all these things, but thats all i can think of right now. 

[Mech]

Is this the manual you are using ?  There's four pages there..  (Just in case it doesn't scroll)

And, have you checked all the stator resistances and pulse output right at the cdi unit, in case there's a broken wire ?

output.pdf

My manual says it's an AC cdi, not 12 volts..  That might be why it smoked !

My manual says that from 95 on it's a DC CDI.

If you are sure it's a DC CDi then I'll post that system..

[mbirt]

I can confirm that my pre-95 KLF220 has spark without a battery installed, so AC CDI it is...