It appears to miss in time with the light, but it is hard to tell if its because the rpm's are so erratic when its missing or if a short is causing the miss. Does that make sense? I guess finding a known good CDI is next. Also if its the CDI would it act up only after the engine is warmed up?
Thanks for all your help.

 

With electronics anything possible! I used to think years ago that a cdi worked or didn't,but have found out different. I posted about one Honda cdi I dropped on ground and machine ran for a little while,a trick I learned from another tech! Still had to replace, but found the problem! Elec problems are most techs nightmares. Keep trying. Timing jumping around sounds like cdi symptom too since its function is spark timing also ( Just like the old points and condensers of bygone days.) Keep trying.

 

is the clearance between ur pulse coil in spec, ur stator is functioning correctly

 

I checked the air gap and its set at .035. My manual says .016 to .040 is ok so I didn't change it. My Polaris dealer wants $260.00 for a new CDI and since I'm really not sure that's the problem I may have to get one of those cheap ones off of ebay. Oh well....my frustration continues.

 

Update......90% sure its the CDI since last night I couldn't get it to start at all. No spark at the plug. First time this has happened since the problem first appeared. New CDI on order.

 

Keeping my fingers crossed for you. Nothing worse than chasing a problem, but since the complete failure of the cdi you have to replace it any way. Good luck.

 

Still waiting on my CDI but get this.......After two days of no spark I hit the starter today and it fired right up. Still had the same symtoms after it warmed up but at least it had spark. Grimlins...I wonder...Oh well. Hopefully the CDI will solve the problems if not I guess its on to the stator.
Thanks again for everybody's input.

 

This mght be way off but my 2004 Polaris was backfireing and it ended up being a leaking muffler, had to order new seals. Did not have the back presure that it needed. It has run better then it ever did.

 

The Good....new CDI arrived and installed.
The Bad......It didnt solve the problem.
The Ugly......More $$$ for a stator.
[img]i/expressions/face-icon-small-disgusted.gif[/img][img]i/expressions/face-icon-small-mad.gif[/img][img]i/expressions/face-icon-small-disgusted.gif[/img][img]i/expressions/face-icon-small-mad.gif[/img]

PS. Thanks for the tip on the muffler but everything appears OK with the donut and main gasket. No leaks that I can find.

 

Just a random thought, but does it clear up when you hit the reverse over ride?