Hi. I have no spark on my 1999 Polaris Scrambler 400 4x4. I discovered that the ignition switch wires were shorted upon each other due to rubbing on the metal frame below the handlebars. I purchased a battery, competely rebuilt the engine-all internal engine electrical parts-excellent condition. (This is the first rebuild) Reassembled engine, atv and turned on the key. I heard a pop then smelled plastic burning from under hood. I cannot document where the smell was coming from-reg, reverse limiter, coil or CDI. The switch was on for under one minute. No wires are bare, melted or such (with exception from connector to ignition switch, discussed before). Let me explain:
There are four wires heading from connector into my ignition switch.
-1 brown
-1 black
-1 red/black stripe
-1 red

I have discovered that the black wire on the ignition was shorted to the red/black striped wire. The brown was shorted on the metal frame. The lights all work, the starter works, the kill switch works, it just has no spark.

So-Old Polaris Tech- or ANYBODY for that matter< can you help me start diagnosing the problem? Step by step? Anybody? Where do I start. I dont have a book, and I am horrible at electrical.

 

welcome to the forum. sounds like you have a dead short some where from the rubbing wires. you might be able to trace bad wires back to where the burning area is to find out where the short is or the bad part.

 

Thanks, Stendori.
Well, all I had to do is pull the black wire from the reverse speed limiter!!!
Also, thanks for all the replies, to all the people, to the forums because I repaired the ATV with minor amounts of money invested!! However, it does tend to throw me over the handle bars in reverse now. Thanks.