2001 Polaris Scrambler 500 4x4 Issue
Apr 12, 2018 | 07:26 PM
#1
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Weekend Warrior
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2001 Polaris Scrambler 500 4x4 Issue
I have been having some problems with my carb on my scrambler. It's always been hard to start and idle. A week ago I pulled the fenders off , gas tank, and carb to replace the carberator. Well got the carb on and find I have no spark. I pulled the black wire off CDI box like the manual says and I get spark. Once reconnected I loose spark. I have been at it for a few days and could really use some help. Also still having issue starting. I have to hold the gas to get it to run and it doesn't idle. And now that I have the black wire disconnected fro the CDI box I can't shut it off. Also I found what I believe to be the REGULATOR RECTIFIER under the nose. Looks to have a few wires coming off it. But the wires are not connected to anything. I have owned this quad since 2005 ish. And it only had 1 owner before me.
Apr 12, 2018 | 09:01 PM
#2
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From: North Texas
Replaced the carb? If it's one of those Chinese clones,it's a lot better to rebuild the better Mikuni carb you already have.https://www.ebay.com/itm/Polaris-Spo...!US!-1&vxp=mtr On this BST40 carb float level is critical. Here's a good article on a similar BST40 and how to set the float level. The BST-40 Bible | Adventure Rider If you have to pull the black kill wire from the cdi for it to have spark then you could have a wiring problem in the ignition switch,left control switch or the switches themselves. Possibly could be the internal kill circcuit on the cdi itself, or a faulty regulator. You can pull the red wire from it leading to the ignition switch then hook the cdi black wire back up and test for spark. Look at this pdf on 1999-to late 2000 model wiring diagrams to help you on the regulator wiring.Yellow,yellow red to stator,brown to group of grounds at the coil mount,plus it branches to the fan ground wire.Red to the ignition switch. https://www.google.com/url?sa=t&rct=...mxEYcQdDfSMeRx OR just get this cheap service manual for your model that can help track down electrical problems along with the carb and other repair,maintenance. 2001 Polaris Scrambler 500 2X4 Service Manual PDF Download
Apr 13, 2018 | 01:26 PM
#3
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Weekend Warrior
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Before replacing the carb the quad ran. Didn't like to idle but it started and I was able to use the kill switch to shut it off. I have wanted to replace to carb to see if I can get it to run better and idle. The original carb was a Mukuni and yes this is an eBay carb. All I did was remove the front plastic fenders, then removed the gas tank, and then the carb. Didn't disconnect any wires. After reinstalling the carb I tried to start with the gas tank connected. It wouldn't start so I pulled the gas tank off and checked for spark. In the manual I have it said to disconnect that black wire going to the CDI. It now starts but I cannot shut off. Under the front plastic I found what looks like a voltage rectifier? It has wires coming off but wasent connected to anything. I did find what I think is another voltage rectifier that is on to of the radiator. That has wires connected to it. See pics.
Apr 13, 2018 | 02:12 PM
#4
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From: North Texas
1st pic looks like the reverse limiter. 3rd pic is the regulator. Disconnect the red wire leading to the ignition switch from the regulator.Again if you have to pull the black wire from the cdi to get spark,then you can have a problem in the kill circuit of the ignition switch or left control switch or in some case the cdi can short out itself through it's black kill wire. Look at the wiring diagram for the late model 2000 Scrambler 500. This can help you sort the wiring and modules out. https://www.google.com/url?sa=t&rct=...mxEYcQdDfSMeRx
Apr 13, 2018 | 08:20 PM
#5
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Weekend Warrior
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1st off thanks for the info and support. Today i got the quad started after I adjusted the idle screw on the carb. It now fires up and is idleing and driving. I rigged up a toggle switch to the black wire from the CDI box to a ground. This allows me to use the toggle switch to ground out the CDI killing the spark. See Pic 1. That is the wire I have going to the toggle switch. In pic 2 there is the connector that has 2 black wires. That is where the black wire going to the CDI box is supposed to be connected. Problem is this connector is always grounded thus killing spark. 1 of those wires goes to the reverse speed limiter,that is the box that isn't connected to any wires ,pic in my 1st post. The other black wire from the connector is going to the on off switch in the handlebar. See pic 3. I am thinking maybe my Run/Off switch is bad and is always grounded? Or since the connector in pic 2, one of the wires is supposed to be going to the reverse rev limiter and obviously isn't connected. I need to trace that wire and see if there is a plug on the other end that is sitting to the frame or something. Hopefully this isn't to confusing.
Apr 14, 2018 | 08:36 AM
#6
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From: North Texas
Sounds like the left control switch is the problem if its black wire is constantly grounded even if its on/off emergency kill slide switch is in the run position. Also could be a problem in the two connectors or wiring in the switch. Clean them and use some electrical grease. If it doesn't help you can either keep the toggle as you have or replace the control switch as a lot of people have done.
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