There is a testing procedure in the manual for the CDI box, as well as one for testing the green and black/blue wires from the pickup. Have you checked continuity from the harness end of the stator to the plug on the CDI on the green and blue/black? Resistance? That wire bundle is routed above the front of the gas tank under the steering stalk and very tightly under the frame, I had a mouse-nest in mine where all of the wires from that loom were eaten/exposed and shorting on one-another. If you lack continuity or have anything over .00 resistance while checking those wires, you may have a problem there.
Other than that, on the spark-front... I am in the same boat as you.
I have a new AGM battery, new coil, new plug, new CDI, and a new R/R... and I am getting no spark. Orange wire to the CDI shows 12v when switched to RUN, 0v when OFF, and I notice no other damage to any of my wires.
At this point I am leaning on it being the pickup near the stator being the issue... but I am not quite ready to rule-out something within the harness being the issue. SO... I am waiting to crack my case open again (just replace the starter one-way bearing)... and am going to take both my original and new parts from the Quadrunner and try them on my good-running KingQuad300. If they all work... then I'm going to crack my case and replace the stator/pickup... then try again.
Unfortunately, I don't have quite the understanding of HOW to troubleshoot the electronics on the bench, even following directions from the Clymer manual. R x 1 means nothing to me... I don't even have that option on my multi-meter... but 20000m, 2000m, 200m, 20m, 20 and 200 all give me different values... none of which match what the damn manual is asking for. Haha.
I think you're supposed to see 1-5v from the pickup when cranking, no more than that though.
Also, I'm trying all Caltric electronics (easily found on amazon or ebay). They are very inexpensive, and are built to the same quality as OEM or better in most cases. I've used them a hundred times on 70's and 80's motorcycles with great luck. I think all the parts have set me back maybe $150? Stator, CDI, Coil and R/R.
"If women don't find you handsome, they should at least find you handy." - R. Green
Last edited by Dan Superchi; 04-15-2019 at 07:06 PM.