I own a 1993 Polaris TrailBoss 2x4...and I'm having one hell of a time with this thing.

It has always run great, but about two years ago I had to "boar" it over because of compression loss, so I went up to a 300cc cylinder boar, and got a wiseco performance piston for it...

It ran great for a few months, but then...without notice, it JUST STOPPED SPARKING. It would not spark, this problem stumped me for about 4 months until I fixed it...it ran for a few months, but then it stopped sparking again...and here I am now, I haven't ridden this monster for a year..and I am about fed up with this.

The first time it did this, I fixed it by simply snipping the override wire (thanks to a friend of mine telling me to try that). But this time I have replaced the coil, the CDI module, and I've checked everything in the book...but it STILL WON'T SPARK.

Any help will be greatly appreciated...thank you very much,
Trent Hopkins

 

if you know how to pull the flywheel off and check the magnets and see if they are corroded or rusted

 

thanks, I'll check that out...I have a chilton's on my model and I've ran all kinds of tests with an olm-meter, they all come out ok.

I've heard a lot of things about switches being the problem, for instance in my case it was the override switch the first time this happened. Any ideas on that? I heard that the ETC switch in the throttle can also be a bitch at times...

open to any suggestions,
Trent..thanks again guys

 

I had problems with my ETC switch not to long ago. What it was doing was backfiring when you let off of the gas. The problem was that the contact return spring under that little cover on your throttell was corroded from water getting in there. I lubercated it up real good and it ran great. But I suppose that if your contact switch went bad all together you would get no spark at all. I would defiently check that contact first of all because it's easy to get at it's easy and cheap to replace and if forgotten that little switch can cause you lots of grief because it controls so much and people just plain forget about it.

 

thanks, I tried that ETC idea...but it is one of the points that seem ok, I checked the switch with an olm-meter, and it has zero resistance when the throttle is un tounched, and some resistance when its pushed...so I guess the ETC is working.

I wish they made quads like they used to, but thanks to this new technology...ETC, the CDI module, and all of these damn safety switches...I have a feeling it is going to be hell finding out why this sucker isn't sparking.

Thanks..
Trent

 

If you have cut the black wire from your reverse speed limeter module then your throttle safety switch is out of the picture. To eliminate the others disconnect the black wire from the CDI. If still no spark check the resistance in the spark plug cap if you havent already. It should be around 5000 ohms. I know its to late but in 9 years of working on these things I have never seen a bad coil so be sure of the problem before replacing coils on these. CDI problems are rare also but I have seen it and I am not so sure that it wasnt caused by voltage being applied to the black wire in at least one case. Charlie

 

Charlie, thanks I think you are just the person that I need to talk to! Right now the black wire coming straight from the module is disconnected (the reverse limiter).

I tried what you said about the black wire from the CDI, but it doesn't help...I have a brand new CDI module on it because unfortunately, I thought that was the problem...in fact a local shop told me it was too, but $200 dollars later I found out that it wasn't.

Right now, I have the sparkplug cap off of the coil wire, exposing bare wire...and I have that wire "hovering" right above the cylinder...but when I pull the recoil there is absolutely no sign of spark.

-been off of the trails too damn long,
Trent

 

anyone know how to test the stator coil or the actual high tention coil? (the one that plugs directly to the plug)

 

Hi I had the same problem with my sons Yamaha the plug boot which was mad of hard plastic has a resister in it that was open. The boot srews off the wire. Try putting just the wire to an engine bolt and see if you get spark.Thats about all that I can think of that is not obvious.

Harry Sp500

 

yeah, I've had that problem too...so I keep that cap off when testing it! I brought my high tention coil to a dealer and they said it tested out ok...so now I'm even more stumped