I had lost all spark on my 2000 xplorer. I checked everything and determined it was the cdi box. So I spend the 150 on a new box and get it last night finally. Put it on and STILL NO SPARK! Then I figure I'll check the pulse trigger or the stator. I get the recoil cover off and notice some pieces of metal on the bottom. I turned the flywheel by hand and noticed through the holes in the flywheel that the stator turned when the flywheel moved. So after about an hour later fighting to get the flywheel off the stator came out with the flywheel. There are 3 small bolts that hold the stator in place and every one of them were sheared off so when the stator turned it cut every wire going to it. I have no idea how it could happen but I've had the worst luck with this machine so I should have figured. Does anyone have any idea how this could have happened? I talked to the dealership and they will not take back the cdi, so I guess I have an extra one now. A new stator is 240. Is there any place cheaper than the dealership?

 

MGM,

Sorry to hear about your misfortune, but I am appreciative of you posting the solution to your problem........as it would be something I would look for if my spark ever died.

About your stator: If only the 3 wires were cut, and the rest of the stator looks to be fine, you could solder the wires back together and put heat shrink tubing over the soldered connections.......hook it back up, and it might work. If it looks like the stator itself is damaged, I would give Ricky Stator a call and explain in detail what you have. He might could rewind it (even to produce more amps) cheaper than buying a new one. He might repair the cut wires as well if you sent it all to him.

I have a friend that works on Polaris machines for a living, and he might would have a used stator for your machine. I would be willing to investigate this for you, if you were willing to give it the extra time that the arrangements might take such as shipping, payment, etc. You might could find one on ebay as well.......who knows?

Let us know what you find out and decide to do.

Waylan

 

Walexa, Thanks for all your help. I hope you don't have as many problems with your xploder as I have. I should have taken the time to diagnose the problem a little more. I have to rebuild my starter and i would have had to take the recoil cover off anyway. I guess you live and learn. I believe that I'm going to try to reconnect the wires and see if that works. I figure I don't have much else to lose. It either works or it doesn't. The only thing is that the stator looks like it's been wearing on the inside of the flywheel. There were shavings all over the inside of the flywheel. Now that i think about it, the charging system has not been working very well over the last 6 months. I have replaced the battery twice not thinking it might be the stator. If it doesn't work after I reconnect the wires, I will either contact rickey stator or just buy a whole new stator. I will post tomorrow after reconnecting the wires tonight and let you know if it works.

 

MGM,

I know what a booger that flywheel can be to get off......I had to take mine off to get it lightened. The center nut was probably the hardest thing to get off, since I didn't even have the cylinder on at the time.

In reconnecting the wires, I would definitely use some heat shrink tubing........you have to put this on the wire before you solder them back together. You probably know what I'm talking about when I say heat shrink tubing, but it is an item that you can pick up at most any automotive store. If the only apparent damage is the wires cut, it will probably be fine once you reconnect them. I believe that since it was off, your timing may have to be reset, depending on if the bolts that backed out go in slots or are a snug fit through the stator. I understand that changing timing can cause the engine to run hotter or cooler, depending on whether it is advanced or retarded. I have a service manual for an Xplorer 400 if you need anything from it. It sounds to me like the bolts that hold the stator on vibrated loose, so I would at least use medium strength loctite to put them back in.

I have had few problems with my Xplorer: Cooling fan went out, swingarm bushings wore out, yoke on rear of front gear box had slack fitting on shaft.....replaced it. I also got my piston too hot and it suffered a light seizure, so I rebuilt it. Other than that, it just loads up sometimes in deep stuff. I'm not sure what causes this, but I believe water is coming up the overflow tube....even though there was a check valve to prevent it. I think I fixed that problem last night: I took a small plastic bottle, and drilled 2 small holes in it, just large enough that I could squeeze rubber tubing through the holes and they would self-seal. One tube goes to the carb overflow fitting, and the other is routed up to the gas tank. I will have to occasionally empty the bottle, but it the carb can overflow, and water can't get in that way any more. Hopefully this has solved my problem. It's a messy way to solve the issue, but nothing else I've tried has worked. I'll find out if that was the problem this Friday night........we're going riding, and it will be quite wet. Sorry for all the rambling, you just never know when something you post might help someone else.

Let us know how it turns out.

Waylan

 

Walexa, I have very good news. I just talked to a buddy of mine at the dealership where i get my parts from. I go to the dealership and buy parts just about every day for myself and other riding friends. Anyways I can return my cdi unit. I guess they didn't want to **** me off and they know what i have been going through with this bike since i bought it from them. I am getting the 150 back for the cdi and for another 65 bucks i can get a new stator. So that is what i am going to do. I figure that if i replace it now with a new one, I won't have to worry about the wires coming apart or just something happening again to the stator. I am so happy i don't have to eat this other cdi unit. Tommorrow I will return the cdi and buy the new stator. The bolts that hold the stator in place are broken off in the plate that holds it in place. I don't know how it happened. I will have to use an easy out to get them out. I will let you know what happens as soon as i get the parts next week. Thanks again.

 

MGM,

Unless more looks damaged other than just the wires, I would try to repair the broken stator first. That would allow you to keep a couple hundred dollars. Soldering isn't hard to do at all, and is very strong. The heat shrink closes up the weld, and protects it from touching anything. Just trying to save you a little cash, as there's always somewhere I'd like to put a couple hundred dollars in my bike other than repairs. You could probably check out the stator to see if it is still good if you know what resistance it is supposed to have.

One thing I would check for sure is to make sure there isn't damage done to the magnets inside the flywheel. Anyway, good luck on whatever you decide.

Waylan

 

Walexa, the outside of the stator is pretty worn down. You can see where it was wearing on the flywheel. The flywheel doesn't look that bad though. There are lots of shavings all over the inside but it think it will be okay. I'm just going to buy the new stator that way I don't have to worry about it. I'm going to order it today so I should have it tuesday. I'll let you know what happens. Thanks.

 

MGM,

If the stator looks worn down, putting in a new one will probably be the best way to go. Instead of starting a new topic, it would be good to revive this one and post results there.......that way all the information is kept together.........just an idea.

Waylan