Hi, I hope someone can give me a few directions here. I bought a bear tracker from a mechanic last summer. (Big mistake!)
My son and I worked on it a little bit last fall and hadn't gotten back to it until now. It was not in running condition when we bought it. I did a bunch of research into problems with them, and found the stator is a big problem with most. I went ahead and began checking this 4 wheeler out, and found it had a bad stator. We replaced it with a new one, and also the cdi just in case.
We just got back to working on it and I'm at a bit of a loss. I've worked on motorcycles for well over 25 years now, but am a bit stumped on this beast. According to a post by rickystator on here, my pickup coil should be reading 500 ohms, and the rotational coil 0 - 1 ohms. Mine has 497 and 0. Should be just fine. I have no spark. The neutral light works (now) so I know that's fine. The neutral relay works fine. The starter relay is bad (just clicks) so I ordered a new one and have tried jumping the relay to start it up. It jumps fine, just no spark. I checked the coil and it seems to be getting no electricity to it. So, I know its gotta be in the cdi section of the wiring somewhere. I've cleaned terminals and connectors until my hands hurt, but no change.
As I stated earlier, new cdi box is on it, and I tried the old one as well, no difference. Can someone here please tell me the electrical flow for this setup? I have a hardbound Haynes manual for bear trackers but some of the wiring colors just do NOT match this atv. Mostly they do, but some wires are different, and some are not shown so I can't trust the diagrams there. Most show only 2 wires attached to the starter relay, but also show 3 or 4 in the connector, but do not show them on the diagram. Any ideas of what else to check, or an electrical flow chart for the cdi system would be greatly appreciated. Thank you for reading.