04 polaris 600 replaced stater cdi box and coiil with all new polaris parts.orignal problem where the wires come out of the engine housing were damaged dont know exactly how damage occured the wires were frayed and several were broken. replaced stater and pickup with new factory stater and still would not crank.thought that frayed wires may have backfed and shorted the cdi box so replaced it still no fire.Will fire one pulse when the engine starts to turn over but that is it.Will not pulse or try to fire until key is turned off and then back on again and then will pulse one time only.have checked air gap on pickup it measures about 10 thousandths with no adjustment ,any ideas what to try next or am i missing something,have almost 600 $ in parts and still wont fire.It has the new Kokusan ignition it was built 2-17-04

 

First thing I would make sure of is all ground wires are tight,making good contact with metal. Plus can't remember off hand but think there is a ground wire on the stator plate I believe also. OPT

 

Yes 2 grounds near the cdi box on 1 screw,sanded and double checked them.1 behind the stater fastens with 1 bolt that holds a wire shield double checked it too..checked the connection on the coil one black one brown wire.Question should there be 12 v on the coil with the key on

 

Voltage goes through the coil only when the cdi is triggered when you try to start it. If you're still just getting one spark at the plug, I'd retrace the steps on the stator installation plus check that you haven't sheared a flywheel key. Plus you might disconnect the black wire from the cdi and see if you have a good spark. This eliminates the kill circuit in the cdi along with the left control switch. Even the left control switch could be faulty or a short in the switch wiring harness leading down into the pod area. OPT
.

 

steps on the stator installation??????????? Do not have any technical manuals and there was no instructions with the new stater,just installed it like the old one come out

 

Then just pull the black wire from the cdi to eliminate the kill circuit to see if you have spark then. OPT