[B4ctrooper]

Hey everyone maybe I’m just stuck on stupid but I’m troubleshooting a no spark on a UTV 500. I don’t know the year but I believe it’s a 2010. It’s been sitting about 10 years. I changed the ignition switch and starter solenoid which were both bad. Now when I crank it to start I get one spark then nothing. It seems to do this every time. Looking at the CDI box there are two plugs that go into it. I haven’t dealt with one that has two plugs so I’m unsure if I can unplug a kill switch wire from it. I have a portable CDI box I plugged in to the trigger coil and I get no spark at all. When testing the trigger coil I had a reading of 110 ohms and when cranking I had .2V AC. I haven’t done one of those tests in a long time but I’m pretty sure I got a correct. Anybody think the trigger coil is bad or is there something else I should be looking at? I’m unsure if theres actually a kill wire at the CDI on this machine. I also do not have a wiring diagram. That’s making this much more difficult

[Davidson310]

Any resolution on this ? I have the same single spark issue on a unit that has been sitting for over 3 years...

[Wedgetail84]

This is a bit of a resurrection, but I feel I have something relevant to offer - and this has been asked twice with no resolution:

I was in a similar boat very recently - I bought a Xinyang XY500GK buggy with a 500cc CF Moto engine/CVT (CF188). It was in a pretty sorry state with the wiring damaged, sun faded and no wiring diagram available. It uses the above mentioned CDI, and using a similar machine’s (IE early C500 quad bike manual) EWD I had the 6 pin plug inputs sorted. But I was getting the dreaded single spark - exactly as above. So I:
-Tried a different coil (from a KL250), same issue
-Built a peak voltage tester, tested the pickup coil (was also getting 0.2VAC on multimeter) - got 3.5v which is good, manual says min of 2.0v
-tried a new CDI, same issue
-fitted a KL250 CDI, got good spark! But it ran like a hairy goat, timing seemed too advanced, which had me head scratching as they’re both specced at 10° BTDC at idle.

I decided the issue must be in the 9 pin plug as everything checked out. My loom only uses three pins in that plug - brake switch, gear reverse and gear idle. Looking at EWDs, these are switching +12v, earth and earth. I decided to ground the gear idle pin, is this seemed the most likely be be switched on during a start or run event. And HEY PRESTO we have good spark!

So my take away - as these CDIs are very universal, if you’ve thoroughly checked the inputs to the 6 pin plug (and you need a peak voltage tester to do this), check your 9 pin plug inputs especially grounding the “gear idle” pin.

This has taken me about 3 sundays and a cooked starter motor of messing around to get that far.

Here’s she is






This is today
https://youtube.com/shorts/bELBQc2oixs?si=f6qufhRlt5eARxmV

Then we took it for a spin before discovering the rear diff pinion had an ungodly amount of play

https://youtube.com/shorts/-6bnJSag3lg?si=U_0HX96JBhheyi6r

[NMKawierider]

Congrats. Getting one to move decently on it's own is a major step.

[Wedgetail84]

Congrats. Getting one to move decently on it's own is a major step.

thanks! I have to admit I was starting to get frustrated and taking it’s lack of running as a personal affront!

I do have a 191R on its way I was planning on putting in it, but it runs so well now I’m not sure if I will anymore