I'm ready to pull out what little hair I have left!! My scrambler had had electrical issues for the last year. I've been fighter a poor spark. I found an old retired tech who traced down my problem to cleaning up the stator last spring.

It's happening again though. I have an external spark tester that works well. It attaches to my plug hoot and ground so I can see how strong the spark is. I can see the spark is very intermittent. I ordered the manual and did all the tests but can't find my problem.... All the resistance and ground tests on the coil, stator and pick-up coil are within spec. I also heated up the coil and stator to see if that was it but very little change with heat. The pick up coil is also within range for proper gap. I hate to just start throwing new parts on it but I think I'm going to bite the bullet and order a new stator and pick-up coil.

Has anyone ever had a stator test well that ended up being the problem??

Frustrated!!!!!!

Paul

 

Clean the face of the pick up coil and the tab on the flywheel and see if that helps.If not double check the pick up coil resistance along with the stator exciter coil resistance from your manual. If this checks out pull the black kill wire from the cdi and see if it runs.Don't over look a shorted 5k plug cap. Remove it and see if you have good spark with the bare wire close to the head.One last thing is to pull the black wire from the reverse limiter module. They can short out(most do) and can retard spark.Module is item#31.Also check if it will recoil start. If it does,could be the pick up is too far out for the electric start to work.Similar to what happened to this member.http://forums.atvconnection.com/pola...ml#post3155476

 

Well I pulled the black wire as you suggested and surprisingly it fired right up. That was good however it will only idle. As soon as I try to give it throttle it dies out. I think it has something to do with that override switch. I'm waving the white flag. I'm ready to blow it up. I'm taking it to a tech as I type…

 

Sorry, I should have added that I did all those things as suggested. It is interesting though and that my low beam is not working and I believe the low beam and override share the same green wire?. Anyway I give up…

 

Might help if you have a good manual with troubleshooting guides and the wiring schematic so you do abetter job of tracing down problems.2003 Polaris Scrambler 500 Service Manual PDF Download Plus you can defeat the over ride completely.
"Trace wires from the override button (gray/white & gray/orange) Cut the gray/orange and tape up both ends. Cut the gray/white and tape up the end which goes to the override button. Connect the other end of the gray/white to the red/white (ignition supplied 12v)"

 

My tech just called and discovered a faulty voltage regulator. Was apparently allowing too much power (16v). Anyone ever had such a problem? We're symptoms similar to mine? (Intermittent spark)

 

Yes a bad regulator can cause all sorts of problems. Too much voltage and it has to go somewhere. Can heat up and boil batteries,blow lights and can in some case cause other electrical problems. Even worse on the newer dci ignition systems.