I just rebuilt the motor in my trailboss only to find that it now doesnt make any spark(it did a few months ago when I pulled the motor). There is voltage coming from the stator and from the cdi box, and i just replaced the coil but still no spark. It reads about 100 V from the cdi box. Is this enough voltage? Also, instead of pulsing voltage as the engine turns over, voltage from the cdi hits 100V then slowly falls. Isn't a sudden cutoff of electricity required to produce a spark?

 

Since you replaced the coil the only tests I have are resistance checks for the exciter coil and the main stator. On the exciter coil check the Brown/White wire to the White wire leading from the stator to the cdi. Should be 120 ohms + or - 20% The main stator Black/Red to Brown White wire should be 20 ohms + or- 20%. If the cdi has a single black wire (kill wire) disconnect it and see if you have spark. If the exciter and stator check out,then it's possibly a cdi problem. Look under your model under "Magneto". Browse

 

I was finally able to check the resistance( Had to get a new Multimeter.) The exciter coil was about 118 ohms, but the main stator seems to be toasted at 138 ohms. Can replace just the stator, or do I have to get a whole magneto?

 

Parts breakdown show # 3083638 as the main stator (separate from the exciter coil) Hard to find for this model,but you might try Ricky Stator(give em a call with this part #) OR you can also try Ricks Stators. Ricky Stator

 

I've done a lot of looking around, and have only been able to find used ones on ebay. Is it possible to repair the stator?

 

If Ricky Stator or Ricks can't help and if the stator is NLA at any Polaris dealer then some generator/alternator shops (if any are close to you) may be able to help on rewinding/repairing any breaks in the wiring. Tough sometimes on finding parts for a 28 year old machine! Later model ones (say around a 90 model or so "IF" they are still available) might work,but you'd have to splice in your connector and no guarantee that it would work.

 

I just got back into working on this trailboss, i still cant figure out this problem with the spark. Im reading about 30V ac out of the magneto, which is converted to roughly 100v by the cdi box. Since i last posted i have replaced the cdi box and the stator. I am still getting a constant voltage from the cdi box and the coil (no pulsing). If i ground the coil I am unable to register voltage anywhere. This seems odd, is there any sort of a wiring diagram i could reference, i am unable to find one?