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Old 04-23-2013, 06:34 PM
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1996 polaris magnum 425 NO SPARK

Hi, I'm new here except through google. I have a 1996 Polaris Magnum 425 that has no spark. I have the service manual and have done every ignition check it gives me and all my resistance checks are perfect. Replace CDI it says at this point. Replaced CDI box and it fired right up. For two days. Rechecked all ignition tests again, same results. Maybe junk CDI box? Ordered another CDI box to eliminate that cause, still no spark. I have traced the wiring via wiring diagram 20 times thinking there has to be something I am missing. Cleaned all connections. Cleaned and checked all grounds. Have power to all places the wiring diagram says it should be. New battery.Cleaned flywheel and checked crankshaft freeplay. No signal to coil. But pickup coil has a bigger gap than spec at high part of flywheel .0050". Shoul be .0040" max. There is no room for adjustments on pickup coil. I'm about to grind slots in the screw holes of the bracket. Figured I would check for any other known or common problems here first. Also checked switches and disconected kill switch. Thanks for reading this long post. Any help would be great. I'm an automotive technician by trade so don't be affraid to get technical.
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Old 04-23-2013, 08:26 PM
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Welcome to the board!
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Old 04-24-2013, 03:50 AM
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Thanks
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Old 04-24-2013, 08:27 AM
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I have a 1995 model that has no spark. I haven't had much time to spend on it. But now that I have 4 425 magnum's I have plenty of parts to swap. One of those 425's is drivable. I am planning on taking electrical parts off the non-running one and put on the running one. When the running one won't start I will have found my problem. My stator I have now is good. The original one was bad,I bought and aftermarket one and has is turned out it was bad also. I was told to adjust the pulse coil gap. The pulse coil gap is non-adjustable. I got a used stator off another atv and I got it to spark a couple times. I am thinking I have a wiring issue or the ETC(electronic throttle control) switch is bad or out of adjustment.
Have you disconnected the black wire off the cdi unit?
Another thing you can do is unplug all of the black wires off the main wiring panel. It should start if all the electricial parts are good. If it starts, connect one black wire at a time till it dies. When it dies trace that wire and that will be the cause of your problem.
I will send you a pm.
Thanks
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Old 04-24-2013, 02:02 PM
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tt425

I have unplugged all black wires, and still no spark. Ect tested good and even tried unplugging both wires to be sure. My pulser coil was'nt adjustable either but a cutoff wheel fixed that problem. May just be time to buy more parts.
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Old 04-24-2013, 03:26 PM
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Not to doubt you but, no spark even when using just the rope pull? It's just that the on-start-run switches go bad more often than you think.
The manual that i have only goes back to 98,in it the air pulse gap is .016"-.040". I'm thinking.020".
You've almost have to have a bad connection somewhere. Key switch?
Check the coil secondary with boot on-10500 ohms
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Old 04-24-2013, 03:44 PM
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4getful2

Thanks for replying.

Today I unplugged every wire on the quad and junction box. Cleaned connectors, used dielectric grease. and even checked voltage drop at every connection. Set air gap to .025". Cleaned all chassis and engine grounds. Had spark for a couple tries on pull start, way intermittent, none on electric start. Checked voltage in and out of key switch and slide switch and have voltage everywhere it should be. Tried Known good coil and wire from Trail blazer also with no change.

Last edited by griffinauto2; 04-24-2013 at 03:47 PM.
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Old 04-25-2013, 08:19 AM
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According to my Polaris service manual on page 10.19 take a look at flywheel key,faulty CDI box, stator wire not grounded, damaged flywheel,worn bearings on end of crankshaft.
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Old 08-21-2013, 10:29 AM
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I am seem to be having a lot of the same issues with my 03 predator 500. only thing is I have 8-10 volts with wire from cdi to coil off at the end of wire while turning over. And when I hook it to the coil and check the volts on the terminal out of the coil. I have none until I let off the start button for a second I have 10 volts then quits. I have done all checks needed I have volts through pulse generator on both side up to cdi. NEw coil new cdi new stator. I don't know what else to do?
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