Go Back   ATVConnection.com ATV Enthusiast Community » Brand Discussions Area » Polaris
Sign in using an external account
Register Forgot Password?
Search

Welcome to ATVConnection Forums!
Welcome to ATVConnection.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the ATVConnection Forums community today!


Reply Share this with your friends
  #1  
Old 09-21-2008, 05:49 PM
Weekend Warrior
Garage is empty, add now
 
Join Date: Jul 2008
Posts: 19
Default Polaris Scrambler Scrambler 500 no spark

We have two 2003 Polaris Scrambler 500's. One died no spark a few weeks ago. Changed spark plug and ran fine. Didn't ride it much, but was running fine. Then we were riding it and it died again. No spark again even with a new plug. Temporary swapped the primary coil (by the cdi box), the cdi box, verified the plug wire and cap and still no spark.

Then for the hell of it I checked the throttle ETC contacts in the thumb throttle on both quads. The quad thats runs fine the contacts were not touching each other and the problem quad contacts were touching. I'm thinking bingo, theres our problem. Adjusted the problem throttle so the contacts are not making contact and still nothing.

Also noticed the brown wire coming out the cdi harness was pretty much broke. Rigged it back up and nothing new, no spark. Also tried disconnecting the black wire from the cdi box, no luck there either.

I pulled the pull starter and removed the two screws for the trigger (pulse) coil and used a meter on each wire and it goes to 0 ohms right away. I read somewhere it should be around 97 ohms, but DOES ANYONE know if this is how you test the trigger coil.

Any suggestions would be great. Thanks in advance. Not sure what else to do. Don't want to spend money on parts unless I'm sure they are bad.
Reply With Quote
  #2  
Old 09-21-2008, 08:33 PM
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
Garage is empty, add now
 
Join Date: Jun 2008
Location: North Texas
Posts: 11,991
Default Polaris Scrambler Scrambler 500 no spark

Should be the quoted resistance BETWEEN both wires of the trigger coil plus or minus 20%,and should not be shorting to ground on either wire. Sounds like you already have your problem narrowed down! Usually I dont have problems with cdi's or coils.
__________________
Retired and loving it! (Main job now,wake up the wife to go to work!)
92 Honda Night Hawk 750 (5500 actual miles)
2000 Chevy Silverado 1500 Sport side (269,000 miles,semi retired)
Whats right is whats left after you do everything else wrong (Robin Williams)
Don't pick a fight with an old man,if he can't fight he'll just shoot ya!
Reply With Quote
  #3  
Old 09-22-2008, 12:20 AM
Weekend Warrior
Garage is empty, add now
 
Join Date: Jul 2008
Posts: 19
Default Polaris Scrambler Scrambler 500 no spark

Thanks old Polaris Tech. Is there away to test the stator and exciter coil packs by using a multi-meter while cranking the engine over? I do not have a peak reading voltmeter, I just have you normal $20 multimeter. Also how important is the brown wire coming out of the cdi box? I assume its just a ground since it goes to the ground on the coil.

Should I just order a trigger coil for rmstator.com take the one off the working quad for trouble shooting purposes?
Reply With Quote
  #4  
Old 09-22-2008, 10:53 AM
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
Garage is empty, add now
 
Join Date: Jun 2008
Location: North Texas
Posts: 11,991
Default Polaris Scrambler Scrambler 500 no spark

Manual shows resistance specs on trigger,charge coil,ign coil,etc. Brown is always ground on Polaris machines. MOST OF THE TIME IS TRIGGER COIL PROBLEM,BUT best to check resistance before ordering parts! Electrical can and sometimes will fool you! Good luck.
__________________
Retired and loving it! (Main job now,wake up the wife to go to work!)
92 Honda Night Hawk 750 (5500 actual miles)
2000 Chevy Silverado 1500 Sport side (269,000 miles,semi retired)
Whats right is whats left after you do everything else wrong (Robin Williams)
Don't pick a fight with an old man,if he can't fight he'll just shoot ya!
Reply With Quote
  #5  
Old 09-24-2008, 02:10 AM
Weekend Warrior
Garage is empty, add now
 
Join Date: Jul 2008
Posts: 19
Default Polaris Scrambler Scrambler 500 no spark

Mother of God, I got my problem fixed. First I would recommend spending a few bucks on a multi-meter. I was using a cheapie and it was not giving me consistent ohm readings. I borrowed a good Fluke and found I was getting a bad reading on the red/blk and red wires going to the stator. I took these readings from up by the cdi box and down near the engine right before they go into the casing. So I was thrilled to find a problem finally. So I removed the flywheel and pulled the stator & trigger coil along with the harness. Once out, I was planning on sending the stator to rmstator and removed the flywheel and pulled the stator out along with the harness. Once out I decided by dumb luck to see what the reading would be on the same wires right on the stator and it tested fine (19 ohms).

With a little more troubleshooting I found the red wire was broke inside the rubber boot that slides into the engine casing. This boot basically allows the wires to run from inside the casing to the outside and be weather proof. Drilled just the red wire hole in the boot, repaired the wire with solder, clear sealer and tape. Reinstalled and almost cried to hear the engine running like a top.

BIG KUDOS TO THESE FORUMS AND OLD POLARIS TECH.
Old Polaris tech, you ever had this happen? wow was pumped when that engine came alive. A $20 factory service manual off ebay and several hours of my time saved us a crap load of money.
Reply With Quote
  #6  
Old 09-24-2008, 10:29 PM
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
Garage is empty, add now
 
Join Date: Jun 2008
Location: North Texas
Posts: 11,991
Default Polaris Scrambler Scrambler 500 no spark

YEP have had wires even come unsoldered from pickup! Most of the time though they are usually shorted internally OR damaged when starter bendixes explode and sling metal around! Pickup coil FIRST to get damaged! Glad you found your problem! Pat yourself on the back and sit back and drink a cold one! Good luck
__________________
Retired and loving it! (Main job now,wake up the wife to go to work!)
92 Honda Night Hawk 750 (5500 actual miles)
2000 Chevy Silverado 1500 Sport side (269,000 miles,semi retired)
Whats right is whats left after you do everything else wrong (Robin Williams)
Don't pick a fight with an old man,if he can't fight he'll just shoot ya!
Reply With Quote
Old 09-24-2008, 10:29 PM
Reply Share this with your friends

Tags
2003, 500, cdi, coil, peak, polaris, problems, pulse, reading, scrambler, spark, stator, throttle, thumb, voltmeter, worst



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On