94 Sportsman 400. After riding for about 10 miles it will start to miss like foulded plug and then quit. No spark. If you let it sit for 30 40 minutes it would run again for a short time until today( I think it is dead Now). If you would let it sit over night it would run again for about 10 miles and go through the same senerio. It would backfire occasionally then quit when this happens. Changed CDI and this was not the problem. I am thinking it is the trigger (pulser) or the exciter but not sure how to check it. I have checked resistance on both. The exciter is 218 ohms and the pulser is open. The exciter has voltage of 2-3-5-10 2-3- 5 volts. It verys as you crank on engine . This is with both the exciter and the pulser disconnected from CDI. The Pulser has no voltage. the CDI registers a 50 to 90volts while cranking and is consant, not verying a lot. Occsional spike to 110volts when you release starter button. Should the pulser make this voltage stop and start? Can anyone diagnose this?
thanks in advance

 

OK After going to this site:
http://www.big-buckatvproducts.com/Site%20Map.htm (remove the hyphen between big and buck to get to this site, for some reason this name is blackballed here)
and using the diagnostic procedure outlined in there Polaris Troubleshooting page, I think I have a bad pulser. If this is the case, does anyone have a source for a replacement without replacing the whole stator? Any help on this or a different diagnosis is welcomed? Please, even a guess or a good lie.....
Thanks

 

do you mean crank trigger when you say. pulser or are you refering to the two exiter coils on the stator. but if big buck doesn't have anything separate you could be out of luck. try finding some used parts as these are great engines right up until someone leaves the stock cast piston in two long and breaks bad then sends broken parts into the crankcase and rendering it junk. that is my advice find on of those. maybe even a whole parts quad for the price of a stator

 

Thanks for replying. I was referring to the trigger. Today I pulled the old stator out and discovered that there was a wire that was broken where the wires go through the engine case. Trigger tests good when the wire ends touch. I hope this is the only problem. I am not quite sure how to repair since the harness sleeve was so brittle and broken from that point and back for about a foot. Wires are also brittle and some have bare spots where the insulation has breaks at that same location. I guess a trip to the electronics shop to see what products are available in the form of a sleeve that I can wrap arround the harness after making the repairs. The seal where harness goes through the engine case was molded with the individual wires in place so this complcates a repair. I could try to mold a seal with silicone at the repair for a couiple of inches outside case but I have not had the best luck with silicone. I am open to suggestions.
Thanks

 

well sounds like you are on the right track. so it broke inside the case that sucks with the plug thing. i'd just try and do all the soldering on that side so you can preserve that plug

 

Actually it is outside the case where all the damage is. If it were inside it would be a peice of cake! One wire going to the trigger is broke off where it enters the plug. The plug is good. I would like to find a compound (maybe a high density silicone sealant) that would adhere to the plug and build on the top of it so it would be like an extension of the plug so as to encase the wire splice and also insulate the other damaged wire insulation. Possibly Permatex Ultra Black will work? I will experiment with some scrp wiring and see if it works. If I can get it to last another 10 years it will have served its purpose!

 

oh right at the plug. that sucks even worse. but ya ultra black permatex. would be my first thought