went out and bypassed brown wire...same same...i also cked it...its a ground and it works..tested the switch too...all good. all back together now and ready for the NEXT round of PAIN..

 

Can't tell if you're happy or sad,if regrounding solved the problem or if you've gone off the deep end..

 

ummm no...that didnt fix it...i tested it and it works thats all....still runs same same...15 seconds and dies....i fixed ZERO...im THAT good....gone NUTZ? too late for that, heheheeheh....so now im on to ordering the cdi next week and try that..;' when i get the cdi ill get rid of toggle switch and wire like its supposed to be...oh get this...it dont matter if the brown wire is on or off...still runs 15 seconds and dies....weather the toggle switch is in the on or off position....BUT...i dont know how this unit works...maybe the ground triggers the charging system and it over charges...heck i dont know...

 

well...part wont be here til next week sometime....i gots a QUESTION...all this crap tied into just the charging unit. if it sparks...what else can be wrong? this cdi thang, if i have spark then i should be good, if i dont then isnt it the cdi/stator?????....charging too id guess. i still dont see why this thing dont run? i wanna say carb myself. plugs foul out after a bit, fuel is getting there/how much now thats a different story.

 

Stator supplies ignition and charging. Resistance checks you said showed to be within range. If the plug is wet and you still suspect a carb problem,go with your instincts and recheck it and eliminate it as a problem.Regulator should have power on the red wire from the stator,but hard to check if it's charging back to the battery if you can't keep it running longer than 15 seconds at a time.

 

thanks....i went back to basics and tried to clean wires on starter solenoid and of course i broke it...FIGURES...now i gotta order one of those too...ill slap the cdi on when it gets here....and get a solenoid. i took the air screw out and almost had it at an idle but then it wouldnt do it again...i should just probably take this thing to polaris up the street and get it fixed...im at a total loss...if i had a good working carb id just try one...then id know, maybe ill ck around and see if anyone i know has one i can just try. thanks again for all your help...its been a BLAST to say the least...

 

i went out this morning and did another test with the new wire on startor the brown one i put in....i did the yellow and yellow/brown...that was supposed to be .17 its .4 and the yellow and yellow/red is .6 thats supposed to be .34...will this make a difference? im still waiting on cdi and starter relay i ordered...the other tests were same as last time. if it is stator i found one that says it fits not sure id have to ck more....

http://www.ebay.com/itm/Stator-Polaris-400-L-Sport-400-1994-1995-Big-Boss-1995-1996-1997-/331311264612?pt=Motors_ATV_Parts_Accessories&hash=item4d23b0b364&vxp=mtr

 

Don't jump at the stator yet as most places won't take the cdi back even if it's in the original package.Just take one step at a time. Charging circuit may or may not be the problem,but if the cdi is already on the way,I'd wait and save the money on the stator until after you test with the new cdi.No use spending more money unless you have to.

 

ok...i wont even though its a great deal...59 bucks for a new stator is good...ill wait til the cdi gets here and see what that does....the starter relay came today..ill put that one on but it worked anyway, i just tried to clean the terminals up and i broke it, my fault.

 

whelp...i got the new starter solenoid
THINGY...i put that on and fooled with it again....NOW i have oil coming out exhaust....of course the fill for sump is broken so i maybe added too much???? thats ok now it wont come out anyway...plastic in an aluminum block...snapped off flush with block...of COURSE under the carb...so ya take that off first. the cdi should be here next weekend ill do that then im done with this thing. too much money into it ill sell it for parts and scrap..my luck the block has a hole in it someplace that you cant see...maybe i should do that presure test anyway....how is that done? piston all the way down? to pressureize the bottom or it just blows past the rings and you do it tdc? let me know when you get the chance....if i slap the pump on it and it wont do anything then its off to partsville/junk bin...ive got 450 into this now and i wont do a block...ill have 500 after i get the cdi...maybe i need to step back...im getting mad/fed up with it...ESPECIALLY when i got it and it ran for like 15 seconds and dies...and all this ive done to it and it does the same thing.