Good evening all:
I have a tomberlin crossfire 150 which has hardly any miles on it. The engine turns over, coughs and sputters, but will not run. I took it to a local motorcycle shop and they diagnosed it as not having a spark. They cannot narrow it down to one specific part but recommended replacing the cdi, coil, and rectifier. Does this sound right and is there a part that is known to go? The battery was bad a few months back and my father tried starting it while a battery charger was hooked up, it hasnt started since. I am afraid this place is just guessing and that I will be spending money for something I don't need.

well not sure if it coughs and sputters sounds like it has some spark,how did the problem all start,how big of battery charger did you have hooked to battery.
pull the spark plug out put in back in plug cap ground spark plug to head and turn engine over.see if you are getting spark and what color it is if its firing.
could be something like a bad ground or kill switch to causing you problems.

if you are getting a nice blue spark might want to make sure your getting good gas flow to carb and carb jets are not plugged up with junk

reread that again and i assume the engine still turns over after hooking battery charger to it.



pud

I have had several CDI boxes burn up in my twister. If the CDI goes, so does your spark from the coil. Check for good spark at the plug while turning the ignition key. If spark is non-existent then replace the CDI before replacing the coil. The coils seem to be a little more resilient. Hope this helps!

I thought the same about it turning over. The spark seems to be intermittent. Could one of the electronic components be causing both issues? Won't run when there is spark and sometimes none is produced?

sounds like a bad ground or wire not making good connection. gently tug on the wires goin into the cdi, if they move then they are not getting a soild connection

yes i would check what BIGE said maybe start at plug were wires plug together from stator, the two seperate wires. check wires plugging into cdi,check wires pluging onto coil.make sure those all those are making good connections.also check were the ground wire or wires bolt down make sure they are also tight no paint under them and making good connection.

how is the key switch is it working smoothly no catching,part the key goes in is it loose lot of movement.i think you know what i'm mean.

after checking everything else and not sure about key switch pull it out.make a little diagram or mark where each wire goes then take them off.
the cross fire wiring diagram i'm looking shows you have a (yellow/green) wire that the hot wire from solenoid,(black) wire coming from main ground,(green) wire is for ground to cdi.when switch is on run position black makes contact with green send ground to cdi,then go over to start hot make makes contact with ground solenoid sends power to starter.

to start with out switch wired up put green and black together,then touch yellow/green to them.if it starts take yellow/green away,leave green black together.if you want to shut it down just take green away from black,thats take ground away from cdi engine will shut down.

now your kill switch its ground to push it or turn it on or off it will send ground back to cdi killing power coming into cdi.

hope that make since,need ground to run but ground will also shut engine down and keep it from running.

to me it just sounds like you a having a wiring connection problem

hope that helps some.

pud