my 1995 Polaris xplorer only starts when I flip the on and off switch back and forth can anyone help me with this

 

Check the connectors going into the control switch along with the wires going down into the headlight pod area for any bare spots. Left control switches do wear out,plus if you take one apart to see if you can find the problem usually springs,small ball bearings tumble out.

 

I replaced the left handlebar switch and still does it the recoil starter came apart and broke one of the magnets on flywheel replaced that and still does same thing no damage to magneto once it starts the switch on handlebar works as it should

 

Then I'd recheck the stator area especially around the pulse coil. If the switch works after it starts,then could be damage anyway in this area. Plus check that the pulse coil gap is between .035-.040 gap between the face of the coil and flywheel. Hard to keep from damaging something if a flywheel magnet comes loose in the stator area.

 

ok ill check that tomorrow the pulse coil is under the flywheel right or is to the left of it would it still run if the magneto is damaged the magnet didn't let go of the flywheel just cracked it in half runs perfect after it starts I appreciate your help this thing is driving me crazy

 

Pulse coil is black module to the left of the flywheel.Flywheel has a raised tab that you align with the pulse coil to check the gap. If it's over .040 you can carefully tap the hold down bracket and move the pulse coil inward a tad.Might be somewhat similar to what happened to this guy. http://forums.atvconnection.com/pola...ml#post3155476

 

ok so I gapped the pulse coil like it was supposed to be the thing fired right up without messing with the switch then it went dead and would not fire again pulled the new flywheel and one of the magnets was ate up along with the magneto had copper broken what could have caused this

 

This flywheel doesn't show to be updated like the 4 strokes with the magnets enclosed. I've had to change out a lot of damaged stators and flywheel on all early machines from weak epoxy holding the magnets. Could be the flywheel you replaced did the damage,but I still suspect you had damage to the stator from the original one.This is the one still listed in Pure Polaris Parts and Cycle Parts Warehouse. #3084760.http://www.ebay.com/itm/Polaris-300-400-Flywheel-Magneto-FF95-OEM-Brand-New-Part-3084760-/161174148114?hash=item2586ba5412&vxp=mtr

 

Can I blues another magnet in its place and what kind of glue

 

Once one breaks,I wouldn't trust a flywheel with trying to epoxy another magnet in place especially if you have to replace the stator. Expensive I know,but best to replace the stator and flywheel and hope the new flywheel will last. Seems to me this flywheel should have been updated just as the 500 flywheel was with enclosed magnets,but since the 2 stroke atvs now are ancient history to Polaris,I guess they didn't bother.Even the last year model 2003 Trail Blazer 400 had exposed magnets in the flywheel.