When we started racing the Cat 90s we removed the spacer. As we got faster we replaced the whole front clutch/variator with a better/cheaper aftermarket one as it had way more range. ie better holeshots and more top speed. A good clutch kit will do wonders too and only costs about $25-$60. You're in there already.

 

I found the CDI it is almost exactly like the one in the pic. I clipped the green wire and the ATV would not start. I hook it back together and it started with it started I seperated them and it stalled out. It will not run with the green wire cut.

 

accwiz

Well that sucks. I will double check the number but I guarantee its the
same CDI I have well my son has. I will even post a picture. Makes no
sense.

Sorry guys.

I'll try to get a pick of the 50 CDI too.

~mike

 

Thanks for taking the plunge on that green wire accwiz! I guess I won't go there now. I stopped at an AC dealer about two hours outside of Memphis today and they didn't seem to know anything about getting rid of the limiter on the '06. (It just seems to be to new for everybody.) They did take the time to look up the parts breakdown and it doesn't appear to have the spacer on the front pulley of the transmission like the old ones did. Maybe they just regulate it all through the CDI box now???

Badvox, what do you think about unplugging the seperate 2 pin harness on the CDI? Also, there is a "resistor" listed in the parts breakdown that is up front just before the gas tank. Could this have something to do with it?

 

Resistor like about an inch and a half long? If thats the one then no.

Check this out. I just looked up my CDI part number and at the parts drawing like you posted.
The part number is the same and the drawing is the same. That is too bizarre.
Same part number but it must be like a rev 2 or something.

They didn't say anything about the spacer in the clutch either?

So not to make matters worse or anything but my sons quad
definitely does about 25mph with my fat **** on it. This is with a pipe
and the rev limiter removed. I left the rear clutch alone for now.
Its being taken out right now for the upcoming races.

Im going to see what I can find out anyway.

badvox

 

The CDI that I have has the same part number but the date is "Aug 2005". Mine with me or my 60lb son will go about 10 mph. I totally removed the tail pipe screen unit and it made no noticible difference. Maybe if that screen were more clogged, but it is pretty clean. My son rides with his friends that have an 02 and 05 polaris 50's and theirs stock go about 15. So he struggles to keep up, which is frustrating for him. I wish if they were going to limit the speed tp such a low end, they would give ways to remove that like that have done on previous years models.

 

Most mini cats have a 50 tooth rear sprocket and the 4 strokes turn about 6000 rpm. The polaris 50s have about a 35 tooth rear sprocket and are 2 strokes and turn about 8000-9000 rpm. Thus 15 mph vs 10 mph difference. If it has a restrictor in the cdi it will get to max speed/rpm when accelerating and sound like it is cutting out. Is the bike doing that or just not going any faster? Do the 4 stroke cats have the same transmission/cvt system as the pics listed?

 

If you are reffering to the pics i posted about the spacer above, our 4-stroke 90 is the same set up with the cover off. Fastdad this spring when the warranty runs out I will be getting with you on a different clutch set up! Thinking about changing the sproket on his bike too but have not checked to see if his 90 4-stroke has the 50 tooth on it or not. Would 35 be too small for the 4-stroker???

 

The older small Cats had a 50 tooth rear, I am not sure when then changed it, but my son's has about a 35 tooth. This AC definately has a limiter. At about 3/4 throttle you can hear it starting to kick in and at full throttle is does the limiter sputter. Also, at full thottle it seems like it has many more RPM's left to give (if that makes sense).

 

I removed the spacer from the front pulley today and the 90 has to be doing at least 30mph now without spit and sputter??? Go figure?? I've started a new thread on it.

Jay