It wasn’t too long ago I had a spark issue and after freshening up the top end it has reared its ugly head again. I have spark with the plug grounded to the head but not while installed in the head. This is our beater quad, the one you grab for those hold my beer and watch this moments. It had major electrical issues when I got it. The 4wd didn’t work and since we already have a 4×4,, carrier and front diff, the front axles, awd switch and overide were removed entirely. The etc is gone, as in removed along with the rev limiter and the wires coming from the shifter. The only wiring left on it is the headlight switch,3 wires from the key switch, the 2 wires for the push button start to work, and the hot wire from the battery to the circuit board. The wiring is strictly bare bones for it to run, charge battery, have lights and shut off with the key and a 7 inch push fan mounted in front of the radiator that is wired to come on with the key. Stator tests fine, coil tests fine along with spark plug boot. have done continuity tests on wiring and it all checks out fine. I am at a loss. Last time this happened it was the rev limiter so I removed it and viola the problem went away. I changed the frame ground, engine ground and ran a ground wire from the coil ground tab to the ground on the circuit board. The grounds are good, triple checked them. Retested stator, coil, and key switch. All are good to go. It ran fine until it busted the skirt off the piston. Had the jug straightened out and got new top end kit for it and put it back together without changing anything about the way it was wired and now it won’t fire with plug in it. Any ideas? All I have left to do is try a different battery. I know it sounds odd to have removed all the safety switches and other stuff that didn’t work and wasn’t going to be replaced but it made it easy to track down the first spark issue. It ran wired in its current configuration for quite a while with no issues and was very reliable until the piston broke. Give me your ideas, opinions, and any and all advice is welcome.

It wasn’t too long ago I had a spark issue and after freshening up the top end it has reared its ugly head again. I have spark with the plug grounded to the head but not while installed in the head. This is our beater quad, the one you grab for those hold my beer and watch this moments. It had major electrical issues when I got it. The 4wd didn’t work and since we already have a 4×4,, carrier and front diff, the front axles, awd switch and overide were removed entirely. The etc is gone, as in removed along with the rev limiter and the wires coming from the shifter. The only wiring left on it is the headlight switch,3 wires from the key switch, the 2 wires for the push button start to work, and the hot wire from the battery to the circuit board. The wiring is strictly bare bones for it to run, charge battery, have lights and shut off with the key and a 7 inch push fan mounted in front of the radiator that is wired to come on with the key. Stator tests fine, coil tests fine along with spark plug boot. have done continuity tests on wiring and it all checks out fine. I am at a loss. Last time this happened it was the rev limiter so I removed it and viola the problem went away. I changed the frame ground, engine ground and ran a ground wire from the coil ground tab to the ground on the circuit board. The grounds are good, triple checked them. Retested stator, coil, and key switch. All are good to go. It ran fine until it busted the skirt off the piston. Had the jug straightened out and got new top end kit for it and put it back together without changing anything about the way it was wired and now it won’t fire with plug in it. Any ideas? All I have left to do is try a different battery. I know it sounds odd to have removed all the safety switches and other stuff that didn’t work and wasn’t going to be replaced but it made it easy to track down the first spark issue. It ran wired in its current configuration for quite a while with no issues and was very reliable until the piston broke. Give me your ideas, opinions, and any and all advice is welcome.