94 will not run after 05 engine install

[Vmax]

I have 5 blasters, and have been going about redoing all of them. One of them is a really clean 94 that I bought that needed a ring and piston. I bought a new ring and piston, put it together, and it ran, idled and everything perfectly. Problem was, the engine was making a noise that I determined was the crank bearings. I ordered new bearings, but I wanted to get this quad running, so I took a good bottom end I had laying around for an 05 blaster, threw my new top end on it, and put it back in the 94. I also cleaned up the carb while the engine was out, since occasionally the float would stick and piss fuel all over the place if you didn't turn the fuel off at night.

NOW....the thing is together, has fired a few times, will not stay running. It doesn't appear I am getting spark. The engine harness has one more wire (green) than the 94 engine did, but everything else matches. I know I do get spark part of the time, since it has ran since the install, just not very well, and not very long.

It also wants to backfire, and a few times when I kicked it, it wanted to kick back, like there was a timing issue.

The flywheel key is not sheared, and it looks like the retaining bolt has never been wrenched on.

I do not seem to be getting current going into the coil, I DO have current leaving the flywheel/magneto.

Is this green wire needed?
Do the CDI boxes go bad on these often?

 

[burnin'_oil_2001]

the only thing different that i know of is the charging system as the stator has 5 wires on the 03-06 models (this is my understanding). maybe this is the reason as it is wired differently. hopefully someone that knows for sure will post tonight for you. i would try one of the ignition systems off of one of your other blasters to see if that is the problem.

 

[Vmax]

I grounded the green wire, and it now runs great. Now I am wondering if I will run into an issue when I put an older style engine in my 05....?

 

[ron89]

when i put my 03 motor in my 96 i swapped the whole wiring harness.. that could be why it will not start. if you have the 05 harness swap em out or you could just swap the older stator into the newer motor..

 

[sc0r1a]

Thats the same thing we did to my girlfriends motor after you ground it everything works beautifully. As far as putting the 94 in an 05 i'm unsure, maybe trying taking the two extra ground wires from the 05 and splicing them together so that the one ground from the motor will plug into both of them.