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Discussion Starter · #1 ·
Hey everyone I’m new to owning a atv. My dad and I are working on this Polaris. We put a new CDI box, new stator, new battery, new fuel pump, and new carb. And new spark and ignition coil. Sometimes it will go and spark other times it won’t stay on. And just dies. Any suggestions will be helpful. Thank you :)
 

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Discussion Starter · #5 ·
so, did replacing all those parts fix a problem or create one?
[/QUOT it fixed it but now we’re running into the issue that is not sparking or igniting and staying on sometimes it does sometimes it doesn’t so now I’m just trying to figure out I’m at a loss he’s at a loss so we’re trying to figure out why and all the old parts were bad they were all rusty and wiring job was all fucked up on the CDI box and we cleaned all that up like everything‘s fine for the wiring and all that now so I’m just running into the issue of why is it not staying on and why is it only sometimes sparking and why is it only sometimes staying on
 

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First, determine if it is a killing of the spark issue or a not making spark issue.

To determine what the situation is, just unplug the black wire from the CDI box and ride it to see if the problem is gone or still there. Note: with the black wire unplugged, you can't stop the engine unless you choke it to death, disconnect the spark plug wire from the plug or plug the black wire back in.

Do this and advise me of the result.
 

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Discussion Starter · #7 ·
First, determine if it is a killing of the spark issue or a not making spark issue.

To determine what the situation is, just unplug the black wire from the CDI box and ride it to see if the problem is gone or still there. Note: with the black wire unplugged, you can't stop the engine unless you choke it to death, disconnect the spark plug wire from the plug or plug the black wire back in.

Do this and advise me of the result.
Thank you I’ve done this already and no spark it just won’t engage it wants to go that sounds like it wants to turn over but wont stay turned over
 

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Just to clarify: cranking and turning over are the same thing - when the starter motor cranks or turns the crankshaft, at the top of each stroke (both compression and exhaust, the ignition fires the spark plug.

Since you determined the kill circuit is not the issue, go back to the basics - first check the compression - as the valves and valve seats wear, the valves lose clearance and the cranking compression drops - the faster the crankshaft turns the higher the compression gets - the first clue to needing to adjust the valves is hard starting. Usually after the initial hard start, a warm engine starts easily until the next day and the situation gets progressively worse.

Not wanting to idle could be a carb or spark problem and either could be the cause of the problem. I can usually determine if it's spark or fuel by using a timing light - I connect the light and just watch the flash - if it flashing while or as it dies, then it's not normally a spark issue, but since you had the flywheel off, there is the possibility that the key sheared and the flywheel is moving while the engine is running causing the spark to be too far advanced or retarded for the engine to run.

Check the spark situation using a new other than Champion spark plug and let me know what the results are.
 

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Hey everyone I’m new to owning a atv. My dad and I are working on this Polaris. We put a new CDI box, new stator, new battery, new fuel pump, and new carb. And new spark and ignition coil. Sometimes it will go and spark other times it won’t stay on. And just dies. Any suggestions will be helpful. Thank you :)
Welcome to the forum
 

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Yes - the Bendix should not be touching the flywheel - I believe the Bendix just pulled out of it's bushing when the cover was removed. Just lift the Bendix out, grease the shaft and put it back in the bushing.
 
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