I have installed the new ignition conversion completely. when I hook up the black wires that go to the kill switch/awd/ignition to the new cdi the wheeler will not start, but if I unhook them it runs fine and kill switch/awd/ignition all seem to work fine also? why does hooking them up kill my wheeler?

 

Which kit the Kokusan or the cheaper RM stator kit? Black wire from the cdi no matter what make is the kill circuit that ties into the ignition switch and left control switch. Could be you have a short either in the left control switch emergency on/off kill switch or ignition switch,but sounds like somethings shorting to ground unless you unhook the black wires. All you can do is trace the wiring and hopefully find the problem.

 

It was the oem kit from polaris, it came with new stator, flywheel, wiring, coil, cdi, and voltage regulator. All 3 systems work with wires unhooked, kill switch stops eveything, awd sends power to front axle, ignition starts wheeler, what do the black wires do?

 

Look back over the instruction sheet,plus look at this video and see if it helps. Something still doesn't sound right.

 

That looks identical to my 600 kit ( the video is a 700) and I hooked everything up the same as the video. I have noticed my black wires all ohm out to 0 but. It also ohms out to 0 if I touch the frame while touching the black wires, so I believe it is going to ground some where, but I don't understand why everything works with wires unhooked.

 

Ok, figured it out, the throttle cable had been turned out and the contacts in the throttle and awd housing were touching, adjusted cable back tight and all is good in the world, thank you for your help and suggestions.

 

Figured something simple was wrong if you had the kit hooked up correctly as you said. Common thing that people over look is too much slack in the throttle cable that causes the etc contacts to touch and kill spark. 1/8" is what is recommended on the throttle lever slack. Tighter than that or no slack at all can cause problems on higher idle when bars are turned fully one way or another.Glad you found the problem..