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2006 Foreman 500 no spark issue

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Hello all, I have a need for some advise.
I have a 2006 Honda Foreman with no spark, I have tested the coil and the stator and both appear to be good.
Not sure how to test the CPI so I bought a new one at $350.00 and still no spark. I noticed the new CPI was getting very hot so I removed and installed the old one and it to was getting very hot. Correct me if I think I have a short somewhere in the harness? The question is where should I start looking?
Thank you all

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Welcome aboard.

 

When you say "CPI" are you referring to the computer under the front fender (aka CDI, ECU) or the voltage regulator under the right rear wheel well?

 

Does your meter show a green light and an "N" on the display when it neutral?

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Yes sorry I am referring to the CDI under the front fender, I just removed the voltage regulator and tested to the best of my ability and it seems ok.

Yes neutral light is on and the CDI box is getting hot.

Thank you for all your help

 

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I’ve honestly never grabbed a CDI on one of these with it running so I don’t know if it should get hot or not.

 

 The voltage regulator should be very hot when running. 

 

So it turns over fine but just doesn’t have spark?

 

@Melatv is the resident electrical genius. 

 

Have you downloaded the factory service manual at the tool bar on top of the page? There is a wiring diagram at the end of the PDF manual download.

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I have not dowloaded the wiring diagram but have glanced thru it. turns over well but no spark. removed the regulator Friday and cleaned all the connections and the ground, tested the regulator with a meter but not sure if tested properly. Meter showed between .241 and .252, I am sure after testing the coil and the stator they are within the limits, Have  (2) new spark plugs and still no spark.

Weird part is the bike was running perfect, drove from my back yard to the front and parked it, 4 hours later tried to start and nothing.

Goin to test the regulator again as I am not sure of that test.

Thank you again for your help and have a great weekend

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Hi Ast M: Try testing the rectifier this way.

 

Here is something I made up for testing the rectifier. If anyone want to add to this do so.

Rectifier test.jpg

 

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