'94 Warrior - stator wiring/CDI pinout?
My son bought a '94 Warrior. It was running fine. His friend stopped, popped the clutch (thinking it was in neutral) and it stalled. Since then, no spark. The wiring has been slightly hacked by a previous owner. Unfortunately they started to work on it without taking any "before" pictures.
Both relays (ignition cutout and neutral safety) have been damaged and are wrapped with electrical tape; looks like they were rubbing on the chain. The electric start works only if I jumper the ignition cutout relay plug between red/white (signal output from start button) to blue/white (signal input to starter solenoid). The neutral relay gets warm after the key is on for a few minutes. Relatively minor issues and can be addressed later, after I fix the spark issue.
The 3-pole stator plug (all white wires) is fine and connected to the harness. The 4-pole plug (red, white, green, brown) has been cut off the stator wiring. The corresponding plug for the CDI (red, yellow, blue, white/green)has likewise been cut off but the color codes not matching is a bit of a problem. This is where the "before" photo would have been invaluable. Can anyone tell me what the connections should be? We've tried a couple different pairings of what they thought it was previously but nothing works. Possibly we may have fried the CDI in the process?
The stator red & white pair show 425 Ohms resistance, should be the pick-up coil if my research is accurate. I believe this is within spec?
The stator green & brown pair show 307 Ohms resistance, should be the pulse generator. I believe this is within spec?
By no spark, I mean no output from CDI on the orange wire to the coil. Hooking a test light to battery + and probing, this shows constant ground (as the light is on) whether cranking or not.
Key switch and shutoff switch on left handlebar tested and working correctly, so I don't expect these to be the cause of no spark.
There is a yellow/black wire on the ignition cutout relay (runs to CDI) that show constant ground, except when cranking; when cranking, there is no ground. Is this correct/expected?
I've read that the stator and CDI are specific to year/model and need to match. Understandable, yes; but also it was working, so the match was "good enough"? I'm really hoping we can just get the correct pairings between the stator and CDI to achieve success...
Thanks all for your time and assistance, it is much appreciated!