I have a 1995 250 Trail Boss. It's old and in rough shape. I have completely stripped it down, sanded it, primed it, and painted it. I have rebuilt the motor and so on. Now, here is the deal. I want to keep it simple. I have removed everything I could relating to anything electric. The Battery, battery tray, starting solenoid, tail light, headlight, oil injection, and everything else is gone. I just want to click one switch and pull start it. Nothing more. I want to retain everything relating to the ignition and magneto only. I want to bypass all the other wiring. I do have a starter, but I have a positive and negative wires zip tied to the frame so I can simply jump start it.

Here is my question. I want to do a simple wiring from the engine magneto to the ignition only. One simple on/off switch. Does anyone have a hand made, computer drawn wiring diagram, or a description on what wires to link from the magneto to the ignition and which wire to switch on and off.

Thank you

 

Look for PN 9912004 . You can find it as free download. It is repair manual for early Polaris
Like all 1985-1995 and it has electrical schematics in it.

 

Not sure of what is all required in the ATV systems to operate, but in a true Magneto system all you do to shut it off is to ground it out and unground to run. You may be able to accomplish what you want by installing a toggle SPST switch to ground in the coil low voltage circuit.

Fred

 

Ok, based on my research, it seems that is all I need to do. Basically, all i want is the ignition. Nothing else. I would like a very simple schematic. Nothing fancy. I see where the magneto simply plugs into the box next to the coil. The the coil has a brown wire that goes to the junction. Is that the ground wire? Also what do the yellow and yellow/red wires do? They go to the junction box.

 

I would think that all you would need is a on/off switch in that brown wire from the junction to the coil to do what you want to do. This would merely make(turn on) or break(turn off) the ignition circuit to power the coil. The Yellow and red/yellow wires probably are from the stator and required to create the voltage to power the coil. I am not familiar with the unit you are dealing with so am not positive about this, only thinking from general knowledge.

Fred

 

Just hook a push switch(like on most dirt bikes) up to the black wire from the cdi module. This is the kill circuit wire.You can delete the regulator,reverse limiter module and all the other wiring if you're not running lights,battery etc. This is just a magneto triggered ignition and only used the battery for the starter and lights. OPT

 

Thank you Old Polaris Tech. You are a wealth of knowledge as always. I would like to delete everything except for anything relating to the ignition. Here is what I know so far. Please advise if this is correct. I keep the spark plug, plug wire, coil, CDI box, and alternator/stator/magneto (obviously). The magneto connects to the CDI via a bundle of wires covered in one insulation.

My questions are as follows:
What do I do with the yellow and yellow/red wire coming from magneto?
What is the regulator?
Can I get rid of that triangular junction box thing?

In the end, if I do this right, should the wiring go like this? The magneto to the bundle of wires to the CDI to the coil to the spark plug. Then ground the black wire to stop the engine, so hook a kill switch to it. There should also be a yellow and yellow/red wire coming from the magneto that will not be used. Is this correct?

 

The yellow and yellow/red wiring go to the regulator rectifier for charging the battery (you say you will eliminate) and can be blocked off.IF you don't run lights or electric starter. You can remove the regulator rectifier and disconnect the black wire from the reverse limiter module(or remove the module itself). Look here under "electrical" under your model on location of these two modules. Then all you will have left is the ignition only and run a simple push switch from the black wire coming out of the cdi to kill it. Browse
OPT

 

Ok figured it out guys. Thanks Old Polaris Tech. Just an FYI, but if any of you have a 1995 250 Trail Boss and want to delete all the old rotten wiring and so one, here is what you do. Grab the thick bundle of wires coming out of the magneto. cut off the yellow and yellow/red wires because they are not needed. plug the harness into the CDI box. Ground the brown wire coming from the harness. The loose black wire coming out of the coil will be the off when grounded wire. Plug in your spark plug and that is it. Get rid of everything else.