2004 Polaris Predator 90 sparks once, then nothing. I just put on my second stater. I have a new coil and CDI. With the new coil and cdi it gets no spark at all. It will light up the spark plug tester but only spark once with a spark plug.

It has a new fully charged battery.
A brand new stater(second one) still the same issue.
The brake light works as it should.
The emergency pull cord works as it should.
The key works as it should.

What else controls the spark besides the stater, coil, and cdi?

Any ideas?

 

The start button itself on the left control switch can cause problems also. You can disconnect the black kill wire from the cdi and see if it cranks up. If it does then check the ignition switch and left control switch wiring. Not uncommon to have to replace either one.Don't say if you replaced the stator,but if you have and it's an after market Caltric or another Chinese brand,they can be hit or miss as far as reliability.Best way to eliminate what the problem is through the trouble shooting guides and resistance checks in the manual.Sportsman 50/90 along with the Outlaw,Predator used the same electrical parts and engines. Just body styles were different. 2004 Polaris Sportsman 90 Service Manual PDF Download

 

The stater is a new caltric brand. I will check the black wire.
Thanks for the manual.

 

I disconnected the black wire with the red stripe, no spark at all.
I reconnected that wire.
I then disconnected the black wire with the white stripe, no spark with a spark plug but, I had good spark with a spark plug tester.

If I have spark with a spark plug tester why am I having no spark with a spark plug?
Does the spark plug take more resistance or?????

 

May be as simple as the plug itself even if new. Check with another one,plus pull the plug cap and let the bare wire rest on the engine.Could be a simple plug cap could be causing the problems also.One other over looked area is throttle slack. If too much lever slack, the etc contacts can touch and spark can be erratic or none at all.Adjust the throttle lever slack to where it has 1/16-1/8" maximum play.

 

It is trying to start. I yanked out the spark plug and did a compression check.
It was at 70, a little low. I am about to order a rebuild kit for it.
Do I need a new cylinder head? A kit without is a little cheaper.

 

That's too low.Minimum 115 psi from the manual,but I know some have run on less.. Some complete cylinder kits out there,don't know how good they are,but would probably be ok. Don't just order a stock piston if you go the other route. Order the next over size piston,have it bored,order new head and base gaskets. May be that's why a lot of people have gone with the complete kits,less hassle.. You can reuse the old cylinder head.

 

Thank for all your help OPT!!!
I think I will just order a complete kit.
I don't want to dump a lot of money into this thing.

 

New top end kit installed, you can hear the difference when the starter is cranking away.
But, still no spark. I get one single spark then nothing.
I have a new CDI, new coil, and a new stator.
This one has me stumped.
What would allow it to spark once, then nothing.
If you let go of the starter and hit it again, one spark.

 

Again new Chinese parts doesn't mean the stator or cdi will work as some have found out.They're hit and miss as far as reliability. I'd still down load the manual and do the ignition trouble shooting checks along with the resistance checks on the stator.It may be the problem.2004 Polaris Sportsman 90 Service Manual PDF Download