fordsoll

So I thought it wouldn't be the key switch because it looks like an aftermarket replacement but I thought might as well check so I looked at the wiring diagram to see how I should bypass it and it looked like I could just disconnect it to bypass it and so I did. The spark was a very nice bright blue and it was pretty thick so using the electric start it started right away. I can't believe it was something so simple I guess I should have tried that right away but the key did look new and it was working before but im glad the problem is solved. Also the engine kill switch was already bypassed so I knew it wasn't that. Thank you all for your time and help.

Ok I went to try to start the quad and it didn't start so I checked the spark again and nothing maybe 1 every few revolutions so I used the drill again to check and there is no spark. Im not sure how to check whether the cdi has a 12v feed in how do I check that? The stator resistance is .300 ohms and the pickup coil is .415 ohms. Can I check the stator ac output voltage by putting the multimeter on ac voltage mode in the same terminals where I ohm tested the stator?

Ok so I took off the recoil and attached a drill (NOT an impact) to the nut on the crankshaft and had really good spark whereas when I used the electric starter I had poor spark. I don't know why the electric starter would have an impact on the spark after all this is an AC ignition system. Anyways I am gonna try starting it with the recoil and I will update this when I try it.

I just installed a new coil and the spark seems a bit better but I have tried a few different spark plugs and 2 new ones and it will only jump the gap on the resistor plug or just the bare coil wire. The bare coil wire actually puts out a decent spark but then through the resistor spark plug cap and the resistor spark plug it puts out a dim purple spark and with a brand new non resistor spark plug that is specified by the manufacture of the quad and no plug cap just the bare wire it will not spark at all.

its a haynes manual that covers a few different quads and I also did notice that the 99 kodiak in the manual seemed to match the wiring a bit better but the sticker on the quad says 1996. The spark will not jump a large gap at all sometime it jumps the spark plug fine and others it needs to be a very small gap.

The spark looks a bit better after putting everything back together but it still wont start I think the spark isn't sparking under the compression of the engine

I meant the location of the pickup coil.

Yeah my pickup coil is good, although the stator on mine is slightly different but its probably fine. Tomorrow I will clean it up and put the cover back on and test the spark again.

I do have the paper manual and yes I will look at the diagram in it to find the ground connections I should check

Is there anything else I should do or check while I have the cover off?

I took off the stator cover and found very very slight surface rust on the end of the steel strip on the flywheel. It looks like someone has replaced the stator before but the pickup coil appears to be in the right position the metal part points straight towards the stator. Is there some sort of alignment that has to be done when you change the stator and or pickup coil? the pickup coil is also magnetic and so are the magnets on the inner part of the flywheel.

The old coil wire just fell apart and you cant replace just the wire. I did try with the old cdi and I just got the same issue the spark is very weak. Could it be the stator or still the ignition coil?

Ok the manual says primary resistance for the coil is 0.36 to 0.48 I measured 0.50 the secondary resistance is supposed to be 5.44 to 7.36 I measured 3.92 maybe these are enough to spark but not enough for a good quality spark? it is -10 degrees celcius outside so maybe it could be that? The specs for the pickup coil is 171 to 209 ohms the multimeter would only read on the 2k setting so I got .415 ohms and the spec for the source coil is 270 to 330 but I again had to use 2k to measure it and I got .300 ohms. It seems like it shouldn't be sparking at all.

It is an aftermarket cdi and coil I doubt its the cdi because when I try the old one it does the same thing. I tested the ignition coil and got .5 on primary and 3.8 on secondary. I tested the spark this morning and every few sparks it would miss and the spark quality is very poor and wont jump a gap much bigger than the spark plug itself which I think is gapped at .025 Plug is new. I will check the pulsar coil next.

I have a 96 Kodiak 400 that suddenly died and didn't start back up again I replaced the cdi and ignition coil and now when I check for spark it is very good but when I put the plug back in the engine to start it it does not start so I checked for spark again and it only sparks every few seconds instead of what it did before. The engine will run if I don't check for spark and just start it right away but I don't know how long because it was just running on wd 40.