Sorry for the long post but want to give all the info that I have collected. My sons '03 Predator 90 started stalling till it would die(about 3 seconds or so, stall to die) after about 10 minutes of riding. Figuring that it was something getting hot and breaking down, I kept letting him ride it, figuring it would eventually fail and I would replace the part, not a good thing to do but. After dieing, something very strange was that it would turn over allday long and not start but it would immediately kickstart. After several shut downs, there was no spark. Resistance readings pointed to bad stator. I replaced stator, and coil, fired right up. After 10 minutes or so of riding its back to stalling and dieing. The (2) 8.5ohm resistors are super hot after a couple minutes of running.

I charged the battery and let it sit for an hour, then took a voltage reading of about 12.5 volts, during cranking it never dropped below 9.5 volts, so I assume there isnt a dead cell issue. After starting, took a voltage reading of around 13V, was expecting 14.6 volts. Due to it not being around 14.6 volts does this point to bad voltage regulator? Does the HOT resistors point to the regulator or something else??

The stalling seems like its starving for fuel. I can clean the carb, etc. If its lack of fuel being the reason for the stall, ok. But my worry, is it something causing the stalling which is also damaging and eventually ruining the $135 stator?? Thanks for any help.

 

sounds like a voltage regulator is blowing other stuff out

 

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Welcome to this forum....

The stator assembly on the Pred-90 has 2 different "parallel" systems. The large single bobin is used to create the spark. The 5 smaller bobins are used to create power to re-charge the battery. In layman's terms.... When the smaller coils spin, they create AC power. The AC power goes to a Rectifier/Regulator. The rectifier converts the AC power to 12V DC Power. The regulator is used to ensure the power doesn't peak 14.3 volts @ 36 Watts. Its much more complex then this but in a simple white board diagram, this is how the 2 parallel systems work. For a picture of these 2 different bobins, surf:

http://community.webshots.com/photo/...52910875YdAizB


When testing a Stator, always ensure to test the "Power Generation" and "Spark" bobins seperately. Sometimes, one can get these 2 systems confused. For example, they feel they need a fully charged battery to obtain a spark off their plug. On the Polaris 90 brands, they are a parallel system. The "power generation" is only used to charge the battery and if installed, power any DRLs (Daytime Running Lights). To view how to test both systems, surf top pictures within:

http://community.webshots.com/album/262582347LVsyKh



For now, try to isolate if stator "spark" problem for fuel flow problem. When your Pred-90 dies, pull its plug and check for spark. If NO spark, perform the above ohms resistance tests. It is rare but sometimes, one can obtain a bad stator replacement.

If spark, then we can assume air flow or gas flow problem. To check gas flow, there's a few tricks that can be done. For example:

- Fill the tank full of gas. Pull the little gas line going into the carb inet and let it gavity drain into a new gas can. Notice the rate of flow out this little tube. If after 5 minutes the gas flow "rate" seems to be lower, then you have a over dirty inline gas filter problem, kinked gas line or air isn't flowing into the top of the gas tank. If I remember correctly, the Polaris 90 brand uses a little air tube at the top of its gas tank. Check to ensure this hidden tube isn't kinked or full of mud. BTW: I change the inline gas filter in our '03 Pred-90 every spring. Well worth it.

- If good gas flow (fully tested with a full tank of gas), then it might be dirt in the carb. Time to clean the carb inside and out. If uncomfortable in this area, remove the carb and take to your nearest auto/motocross shop. They have special wash tubs and solutions to clean carbs.

- No related to sudden "stall outs" but does impact carb jetting. Pull your air filter off and give it a good washing. If old, replace the air filter material. I replace my mini's air filter material every 2 years.


If you suspect its NOT a gas flow, dirty carb or stator "output" problem, another area to investigate is dirty switches. If dirt / crud in the switches (Key &/or kill switches), it may cause the mini to "stall out". Make it act like a gas flow or stator problem. When checking switches and connectors, do add some dielectric grease to all electrical connections. This little tub is expensive but does reduce electrical flow problems on all minis. Especially "mud or crud" running minis.


BTW: The Rectifier / Regulator and other electrical parts can be very hot. Especially if driving in a hot climate. If yuo have access to another Polais 90's electrical parts. For example, someone with the same mini on your trails. Touch their electrical parts to determine if their parts run hot as well. If so, your hot parts are normal (for the design of the mini).


Give these items a try and let us know the outcome. Hopefully, its only something silly - like a dirty inline gas filter.


Hope this helps...


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