Just as an FYI re the red stator wire...
The stator and CDI's firmware (it is a small computer) used on the 660 hasn't been changed much since the engine was originally used on a kick start motorcycle in, I believe, the early 90's.
The red and red/white stator pair is called the 'rotation direction winding' and was used by the CDI to determine if the engine was turning backwards - which would sometimes happen if the engine kicked back from the compression stroke when kick starting. CDI detection of reverse rotation would prevent spark from occurring.
They didn't change this stuff when they turned the engine into an electric starter for the Raptor - no need to fix it because it was just a feature that wasn't needed anymore. What they didn't realize was that many years down the road, a common failure of the stator was for the red and red/white winding to lose its insulation and short to one of the charge windings - causing the CDI to THINK that the engine was turning backwards... so the software in the CDI turns off the spark! OUCH!
Unplugging the regulator disconnects the three charge windings from everything else, so the short no longer passes any voltage to the CDI and VOILA, spark returns.
So, cutting the red stator wire (if spark has been lost but unplugging the regulator lets spark return) simply removes the false CDI information that the engine is turning in reverse... thereby returning the spark that the CDI had been inhibiting.
An added bonus is that this signal is somehow summed with the pulse coil signal and used to set the reverse RPM limit, when in reverse. Cutting the red wire removes one of the two signals that are added, and so the RPM limit goes way up.
Hope I didn't bore you.
'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
Last edited by QuadManiac; 09-18-2013 at 08:31 PM.