ok guys i finally had a little time to try and track some things down. the numbering out of my cdi from the diagram posted is a little diff.
1-blue/white tracer to stator
2-black/yellow tracer to coil
3-green/white tracer goes to kill switch
4-empty
5-black/white tracer to kill switch
6-black/red tracer to stator
i have power coming into and out of start switch, but still will not crank motor by turning key switch. you can feel and hear the selenoid clicking. both wires to the selnoid test hot. you can cross selenoid and turn the motor with the key switch on but still no fire to coil. tried this with the kill switch unplugged and plugged.

there are 5 wires coming from the stator. green, yellow, pink, blue/yellow tracer, and black/red tracer. with key switch on and crossing selenoid the only wire from stator producing fire is the black/red tracer.

the black/red tracer wire go to cdi(#6) in a plug with black/white tracer(#5) that goes to kill switch. with that plugged in and other 4 wires on cdi unplugged, #1 and #3 show power, nothing out of #2. when you plug that plug in you get no power out of #1. all this testing was done with key switch on and crossing the selenoid to turn the motor.

i also tried all this with the rectifier plugged in and unplugged, made no diff. either way.

sorry for the long post, but i am trying to get as much information as possible to help you guys understand.

i also forgot to add that i did check all grounds and they are good.

well i will be honest i'm some what confused.what year buggy is this???
now some one might want to comfirm this but i think i have heard that no.3 and 4 plug are both ground and the ground wire could go on either one.
the (green/white) ground wire i would think would go to key switch not the kill switch
now the (black/white) on no.5 would be for kill switch and when switch is pushed or turned on or off it will pick ground up sending ground back to cdi killing the power.

with the 4 wire plug unplugged and turn engine over you get power out of no.1 and no.3
thats a good sign that the magnetic pickup is working,blue/white wire
but what do youn mean about power on no.3 that should be ground.do you mean your getting AC volts through the green/white ground wire. and are you using a multi-meter to do your testing.
how well did you check the wiring maybe i'm clean out there in left field but it sounds like you have some wires together some where with the other problem your also having
i will think about this some more

pud

i am using a 12volt test light not a volt meter. this cart is a 2005, or a leftover 2004. it was bought in feb. 2005.
after looking again, the green/white could go to kill switch or key switch, each one has a green/white wire. the kill switch has a green/white and a black/white going to it.
i guess i am going to have to take the seat out and undo the complete harness. maybe something is shorted out under the seat. it just doean't make any sense to me. it is weird that the #1 out of cdi test hot but when you plug it in you get nothing out of it.

well it could be a bad cdi i guess but i'm going with the other problem your having to.
using the test light the green/white wire had power to while you turn engine over, unplugged from cdi????
red/black wire will be ac volts power from stator to power cdi.blue/white is ac volts from magnetic pickup but it doesn't make to many volts, to let cdi know when to send power to the coil, through black yellow wire.

pud

the #3 spot on the cdi puts volts out with the plug unplugged. i am getting very confused i am leaning towards bad cdi too but why will it not turn with the key switch? i think it also has a bad selenoid.

well sorry ridered14 if i'm confusing you but in all honesty i think if you find the problem why it won't turn over by key then you will have found your other problem.
from your very first post something has been hot to do the damage that you said.thats why i thinks its in the wiring something had to cause that.
on getting the cdi and new solenoid thats going to have to be your call they don't cost that much on always handy to have.i know its got to be frustrating.
if i was there i would lend you a hand.

pud

thanks pud, i appreciate that. where is the best place to get these parts. carter parts are pretty expensive. can you use diff. brands? i have alot more looking to do.

thanks

yes you can use different cdi's from different brands. the year of your buggy it should be the black AC stock 9000 rpm cdi.
solenoids that i have seen are the same just different plugs on them where they plug up but i never let that bother me just put my own ends on.

anyone of the dealers here will treat you wright,good fair prices and fast shipping.thats why there here

now BIGE at mcdonough powersports should have what you need, he is also a carter dealer.give him a shout i'm sure he has worked on that style buggy and year before and could give you some advice on things and wiring if there is a problem there.

good luck hope you get it straightened out.

pud

well i had a chance today to take the complete harness out of the cart. no problems there. everythong looks good. it has to be something in the components. maybe a combination of a couple of them. i will try mcdonough tomorrow and try to get some answers.