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  1. Hello! First time poster here, looking for help. This will be long, but I want to give you the whole story. I'm very confused because I am a fairly experienced mechanic but must be missing something. A friend who is not mechanical brought me a 2003 Eiger 400 automatic that didn't run. A quick inspection revealed that the motor was seized. I pulled the top end and found the cylinder and piston rings were rusted together from the machine having been submerged at some point and then left to sit for several years. I put in a new piston and cylinder and checked the valve lash. Compression test today was 150 psi. Replaced the corroded vacuum petcock with a Yamaha petcock, cleaned the fuel tank out, and replaced all the fuel lines. Replaced the badly corroded carburetor with an Amazon aftermarket model (with good reviews) and it wouldn't start. Found that there was no spark so I substituted an Amazon 4-pin CDI box and found that I now have good spark. It still wouldn't start so I used a little starting fluid and it fired right up for about 3 seconds. Now, after cleaning and checking out the new carburetor, I have found that when it cranks and fires, the engine actually kicks backwards momentarily and then resumes cranking. It is acting like the spark is way advanced and it is firing before TDC. I know that it is turning backwards momentarily because I still have the recoil off and I can see the starter cup rotating and then literally stopping momentarily when it fires. I've had the flywheel off to check the magnets and the woodruff key. The flywheel does not have the exposed magnets, but the fully enclosed magnets like the replacement RMStator flywheel. The woodruff key was in perfect condition. The pickup coil resistance test was good. Since it seems like a timing issue, I pulled the cylinder head off again and double-checked the timing. It did appear that the timing marks were off by one tooth, so I corrected that and thought that I had found the problem. Unfortunately, it still does the same thing...It will crank just fine, but won’t start, and kicks backwards when it fires whether I use starting fluid or not. Since the timing is not adjustable on this machine, I’m wondering if the factory CDI circuitry incorporates any type of variable timing feature that is dependent on RPM? That is about the only thing I can think of. I've read other threads that discuss this "kickback" symptom and the usual culprits are weak battery or a too lean condition causing preignition. I've installed (and charged) a new battery and triple-checked both carburetors...the original one that I completely cleaned, and the Amazon replacement. Same response with both carbs, which leads me back to questioning the CDI. Any body else run into this? Thank in advance for your help.
  2. Hello, I have a 2004 Yamaha Bear Tracker in the shop for repair. I have the service manual but it doesn't have all the information I need to fix the problem. I need to know the voltage output of the stator charge coil and pulse or trigger coil at cranking speed. The wiring diagram color code doesn't seem to match and that is compounded by the fact that the wiring harness CDI connector is missing so I have 7 wires that need to be connected to the CDI. I can not find a circuit diagram of the CDI which tells me where the pulse/trigger coil connects or the charge coil connects. The other 3 wires (black ground, orange ignition coil, and r/b ignition kill sw) also need to be connected. The CDI has a single 8 pin connector and has a P/N 4XE-00 F8T19871 -1122 number on it and I believe it to be OEM. However I think the Stator and pulse coil are aftermarket items. I have resistance tested everything and it all seems to be in spec. but I don't want to miss wire anything and cause damage. Any help would be greatly appreciated.
  3. My 98 grizzly needs a cdi and I refuse to pay $200 for a used one. Will the cdi unit for CDI Box For Yamaha Kodiak 400 YFM400 2001 2002 Warrior 350 YFM350X 1997-2001 work on a 98 grizzly ? Any ideas
  4. new racing cdi trz50 wiring for predator 90 cdi has a green and yellow wire going to a 2 pin plug and has a red a black and blue with bullet connectors what wires go were on the the ate wiring harness and how would i wire if i want to bypass the atv harness
  5. Have a 2000 Yamaha Grizzly YFM600FWA with no spark. Checked the troubleshooting chart, and all checks were within specs. CDI has part # 5GT-00 F8T36071. Friend has a 1998 Grizzly 600 but his CDI part # is 4WV-00 F8t34671. Are they the same? Thinking about taking my CDI and put it on his ATV and find out if it works, but don't want to damage something if not interchangeable. Thanks
  6. 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.
  7. I have worked about 4 weeks on my Griz600 and have burnt 2 CDIs up ! I added a wire harness and stator and It starts but runs erratically like spark timing is off ! So I would like to try another CDI but I don’t want to Pay an arm n leg ! Anybody have one ? Thanks
  8. 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 IMG_4379.MOV
  9. 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 ! IMG_4272.MOV
  10. 1998 Grizzly600 ! Slowly died then wouldn’t start ! All coils check good ohms ! Checked ac voltage from source coil get OL ! Is the source coil bad ?
  11. I have a 02 Warrior i am trying to build a wiring harness i have looked in the manual and i am confused... the pick up has 2 wires. W/R W/G The source rotation coil has 2 wires. One is Red other is white/blue. The manual shows the the white and blue wire connected to the w/g right after the stator... so why is these 2 wires connected? Does not show w/b wire at cdi i have looked at many options with no luck if someone has a 2002-2004 warrior and can take a pic of the wires and location at cdi i would really appreciate it. Thanks
  12. I purchased a CDI box from Ebay that was listed as the one for a 200trx with round plug.....when I plugged it in the reverse light stays on.....what did I do wrong ? or is it just a bad CDI box?
  13. Hi guys im new here and ive been doing alot of research on my polaris predator i was wondering if anyone on here has wired a different cdi up on there quad? Not a direct replacement that would simply just plug in. I know my white an w/red wires go to my pulsar my green an blue go to my reverse coil but im unsure which is + and which is ground also brown/w is a ground correct? What about purple? Black goes to my kill switch and red is my 12v supply........then ive got yelloww/red , yellow / yellow that goes to my rectifier..........any input on this subject is greatly appreciated thank you all
  14. I came across an odd temporary fix for a 1985 yamaha 80 ATV. It has no spark, yet if I warm the CDI unit up a bit with a heat gun or hair dryer then it fires right up and runs fine until shut off then it returns to no spark until warmed up again. Partzilla shows $217 for a new CDI It's sort of nuts how I found out the fix to warm it up. My old shop TV requires my heat gun warm up around the transformer area every day before it will turn on too.
  15. I have a 400 4by4 ,2005 green model, wounding how many different CDI boxes will work on it
  16. So here's my situation.i picked up a super clean 225 moto 4 but the cdi has been cut off.i have numerous different cdi units and just can't simply afford to buy anything currently.im sure I can make something work I'm just seeking a little advise or ideas or thoughts. Any help would be greatly appreciated.thank you
  17. Hi Guys I have 88 4trax FW , it has a booster circuit In the cdi control fed from a leg in the alternator. MY Honda service manual says you will get no spark without this circuit on this model. Can someone explain a little about this please ? Thanks
  18. Hello. I'm new to this forum. I just bought this big bear. This thing is show room condition. Now I haven't had time to dig into it so it might be easy to fix. But the guy I bought it from said it needs a CDI box. Now is there away to test these to see if it's bad? I see they are hard to find. Any recommendations on batteries? Any help would be greatly appreciated. I'll get back with results one I get time to look at it.
  19. First thanks for any help guys, new to the forums and it's gotten me this far. I bought a 2001 bear tracker 250 for my family to get around the dirt bikes races. It wasn't running right and had a high idle. Previous owner thought it was a carb problem, so he ordered a new Zoom carb and new intake boot, but it still had the same high idle. ( I believe he had the throttle cable adjusted wrong, because it idled fine when I put it back together) So I tore down and cleaned the stock carb, and it started up and idled fine, but needed to have the choke 1/2 out to run. I swapped to the new zoom carb and had the same issue. Choke half out bike ran ok. I played with the needle and the pilot screw with no change. ( bike did seem to be running rich though, but didn't get better when I tightened pilot screw or raised meddle) I Took it to the races and once I started bouncing around in the cattle fields the quad started cutting out real bad. It would barely run. Sometimes it would run with choke off, sometimes choke 1/2, sometime choke full. I cleaned carb again, checked float level, and boots, no change still wouldn't run. Then suddenly it started running ok again. This makes me believe it's an electrical issue rather then carb. I know there's no air leak, it's been checked, both carbs are clean( I've swapped them out a couple times, it starts up immediately and usually idles fine. But then bogs down/ or stutters under throttle. I saw the post on the guy who disconnected his rectifier and reconnected and suddenly it started working again, which lead me to believe it may be electrical and not carb. So any advice on what I should check? Any way to test the CDI or rectifier? Once again, I appreciate your help.
  20. Anybody know if its possible to use a cdi off of a 95 bayou and put it on a 96. femalke and male conects are different
  21. I have a 08 TGB Outback 425 had it running yesterday went back to start it later didn't start checked and no spark went over all wires and connections can't find problem the atv has all good fuses need help.
  22. I may be faced with buying a new ignitor for my '04 Prairie 700. I'm considering going the aftermarket route since they offer performance enhancements along with being a fraction in cost compared to a factory replacement. Guess that leads to my question, which manufacturers produce the best part? I see glowing reviews for Dynatek but there are also a few complaints about issues out of the box. A good thing, it seems Dynatek is willing to work with the customers on resolving problems. If anyone here has experience with them or others, good or bad I'd like to hear it.
  23. New aftermarket CDI that has been tested for sale! Had I been to this site first, would not have gotten wrong part! My loss is you gain! It is on ebay starting at 99 cents! eBay item number: 261580659437 Happy Riding!!
  24. I am looking for a cdi box 1988 yamaha warrior 350 xu. I need one badly thanks if u have one for a decent price.
  25. Dear guys, I just have a problem as my CDI box and its connector was taken off my bike (KFX700). I already got a Procomm replacement unit but as I do not have original connector I cannot connect it. Could somebody post pinout of CDI or a picture of connector where wires color and position can be seen clearly? KFX700 2005 Thank you for your help
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