01 trail boss 325
#21
IF you're sure the stator wires resistance checked out ok,pull the black kill wire from the cdi and see if you have spark.Plus pull the plug cap and check with the bare wire leaning on the cylinder.Simple resistors in plug caps can short out also. Also move the emergency kill switch back and forth several times. Moisture can get into this control and mess up ignition also if the contacts get corroded. Plus check that the connectors leading into the left control switch are clean and tight. If you have spark after pulling the cdi kill wire,problem can be in the ignition switch or wiring or left control housing or wiring.Plus rare occasions the cdi kill wire can short out internally and can only run with it unplugged.Have to choke it down to kill it. Found several like this over the years. Try these checks first,then check it with the used cdi you bought. Also pull the black wire from the limiter module. Another module that can short out and cause problems. Item #18. http://www.cyclepartswarehouse.com/f...2001&fveh=5535
Last edited by old polaris tech; 02-23-2015 at 07:43 PM. Reason: limiter module
#22
IF you're sure the stator wires resistance checked out ok,pull the black kill wire from the cdi and see if you have spark.Plus pull the plug cap and check with the bare wire leaning on the cylinder.Simple resistors in plug caps can short out also. Also move the emergency kill switch back and forth several times. Moisture can get into this control and mess up ignition also if the contacts get corroded. Plus check that the connectors leading into the left control switch are clean and tight. If you have spark after pulling the cdi kill wire,problem can be in the ignition switch or wiring or left control housing or wiring.Plus rare occasions the cdi kill wire can short out internally and can only run with it unplugged.Have to choke it down to kill it. Found several like this over the years. Try these checks first,then check it with the used cdi you bought.
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