1995 Magnum 425 No Spark - Polaris ATV Forum
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post #1 of 8 (permalink) Old 03-27-2013, 06:55 PM Thread Starter
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1995 Magnum 425 No Spark

I'm working on a 95 Magnum 425 4x4 for a friend. I pulled the motor to replace the water pump. I put it back in and started it with everything put back together except the fuel tank bolted in and the plastic attached. It ran good and everything worked. So I bolted down the tank, put on the plastic and racks and now it wont start.

I pulled enough plastic back off to get to the spark plug and found I have no spark. I've checked all the wires to see if anything got pinched or unplugged and it all looks good. What's strange is although I have no spark, as I crank it, if I turn the key or kill switch off I get 1 spark. Same if I pull start it.

I read on here of someone having a similar issue and it was the pickup coil air gap. I tried bending it closer or further from the flywheel and I still get the same result.

I unplugged the black wire from the CDI as my manual said that would eliminate the saftey switches from the circuit and that didn't change anything either.

Help!
Steve
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post #2 of 8 (permalink) Old 03-27-2013, 07:31 PM
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I know this sounds crazy but have you checked the flywheel to see if it sheared the keyway? Check all electrical connections and make sure its in neutral inspect your flywheel to insure that the magnets didn't come off does it have a throttle override system???? If it does adjust your idle up a hair inspect you coil for any cracks it sounds like something stupid
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post #3 of 8 (permalink) Old 03-27-2013, 07:40 PM
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another thing check your rev limiter or voltage regulator
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post #4 of 8 (permalink) Old 03-28-2013, 05:16 AM Thread Starter
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Thanks for the ideas. It does have the throttle override system, I pulled the cover off that and made sure the switch contacts opened and closed, that didn't change anything. The flywheel looked good, the magnet is in place and I used a little steel wool on it to clean up the surface rust.

How would I check the voltage regulator and rev limiter?
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post #5 of 8 (permalink) Old 03-28-2013, 05:27 AM
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I'm almost positive its the rev limiter my dad had the same problem on his 400l no fire until we changed that box and wala fire but be sure that if you do buy one its nos and not used someone sold us a usedd one and it was bad too yea go figure that was a pain in the ass dealing with that after rebuilding the top end on it only to find out no spark the whole time when we did a compression test after it wouldn't run it had 30 psi and we didn't even think to check fire til it was all put back together
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post #6 of 8 (permalink) Old 03-28-2013, 02:58 PM
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I have been working on a 425 with simialar issues. I have checked everything I can think of. Stator ohmed bad,exciter coil was bad also. Bought a new one aftermarket $150 later it had a bad exciter coil. Got a good used stator and put on it. Got it to spark a couple times but it didn't start. I am thinking my problem is the cdi box. I will be working on mine this weekend. I am gonna tear down my running 425 and put parts one at a time from the non-running atv to the running atv. When it don't start I will know what the problem is. I will post on my old thread or this one what I find.
Some older polaris models had a problem with the fuel tank rubbing the spark plug wire and breaking it down causing it to be bad.
I hope you figure it out.
Post your results.
Thanks

2008 Dodge Caliper
2010 Chevrolet Equinox
2004 Honda ForemanES 400 4x4
(Currently I don't own a Polaris but I work on them all the time and get to ride cutomers for test rides. Maybe soon I will be a Polaris owner.)
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post #7 of 8 (permalink) Old 04-17-2013, 09:36 AM Thread Starter
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Thought I would come back and update this. It ended up being the pick-up coil. Bought a new one from Ricky Stator and it fired right up. Hope this helps someone else with the same issue.
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post #8 of 8 (permalink) Old 04-18-2013, 06:30 PM
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1995 Magnum 425 No Spark

Great. Ricky stator is a real good company. Customer service is above and beyond the average companies.

2008 Dodge Caliper
2010 Chevrolet Equinox
2004 Honda ForemanES 400 4x4
(Currently I don't own a Polaris but I work on them all the time and get to ride cutomers for test rides. Maybe soon I will be a Polaris owner.)
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