skidude67 - If he disconnected the wire harness for the right side of the bars (kill switch, thumb/handwarmer) the sled will run and the right hand warmer will be off. When you press the kill switch it closes the connection to ground and kill the motor.
When the REV kill switch fails its usually keeps the connection open so the sled still runs. As the switch wears the plastic gets into the contacts and wont allow the sled to turn off. Mine has this problem occasionally. I have to hold the button down so it turns off. To fix it you can take the switch apart and clean the contacts.
trailshredder - The 05+ REV has a high output 360watt stator. I have not heard of many issues with them? Some older doo models had stator issues such as the late 90s 800 tripples.
renegade_x - Hook everything back up again and make sure you are grounding the spark plug to one of the engine head bolts. It wont spark if you hold it on the aluminum head.
Possible causes of no spark would be:
MPEM, DESS Post, ground issue / exposed wire shorting out, Stator, kill switch
It sounds like you were riding off trail when it stopped working?
The MPEM (computer) is mounted directly under the headlight. Snow hits the headlight, melts and water drips directly into the exposed wire harness. My guess is this is where the problem is. You could inspect the harness connection on the MPEM for corrosion. The risk with this is if the pins are corroded it may be difficult to remove the connector and they could break off inside the MPEM. There is a tech bulletin to add dielectric grease to the pins. 2007 Doo added a rubber boot to the harness connector to correct this problem.
