I have a 2003 polaris trail boss and im not getting any spark from the spark plug wire. Idk what to do and i have a wiring diagram and i understand it, but idk why im still not getting a spark to my spark wire. please help me
Model: Trail Boss
I've have hooked up a new ignition coil and correctly. Then I took the housing off of the fly wheel and cleaned up some corrosion inside the housing and made sure the magnito wasn't fried. I just don't know what else to do, idk how you can figure out if the CDI system is bad. It will turn over with the starter but it wont give me a spark to my spark plug please help me.
disconnect the kill switch system first by disconnecting the black wire from the cdi unit then see if you have spark then
that worked what does that mean though?
a couple of things it could be a miss adjustment on the thumb throttle. the run stop switch is bad ignition switch is bad or the reve limiter is bad.
how would can i check to see if the thumb throttle isn't missing? what should i start with if you don't mind me asking. I new to all of this and i've never worked on a four wheeler before but i understand the wiring diagram i just need a step by step guide to check the tun stop switch and/or see if the ignition switch is bad or the reverse limiter is bad.
check the thumb throttle it should have some free play but no more than 1/8 of an inch of free play.
with a volt meters positive lead on the positive battery terminal and the and the meters negative lead on the black wire to the CDI box. with the connector disconnected from the CDI unit. you should have show voltage as the black wire is ground to kill the spark in the system. then dis connect one component at a time. when the volt meter goes to zero that is the component that is causing the no spark issue.
Yamaha Gold, Suzuki Gold, Honda Bronze, Polaris Bronze, BRP
thank you very much, that helps alot more than you think.
oh and another thing i was curious about it looks like my carburetor has two fuel lines going to it. nad i know that one of the valve ends had broken off on the fuel pump where it says P- I think it means impulse valve where does that hook up and why is there two lines to the carburetor? can I put in an inline fuel pump for a cheaper alternative, or do you have to have the impulse for the carburetor?
i hardly ever see the fuel pumps go bad on this units. one hose is the fuel line and the other is the vacuum hose that causes the pulse for the fuel pump to pump the fuel to the carb.
do you have a diagram where i can see how everything is hooked up fromt he fuel pump to the fuel vavle to the carburetor then to the fuel pump. I guess i get confused when theres only so much you can do with only so many hoses lol
could there be nothing wrong with any of the wiring system at all, like the throttle and the run stop and the reverse limiter, could there be nothing wrong with any of it?
7. Fuel Inlet
8. Fuel Outlet
the remaining port is for the vacuum pulse
it could also be the black wire itself is shorted to ground.
so am i supposed to leave the black wire from the CDI box unplugged while i check the other black wires? and I was wondering, could i still run the 4 wheeler if black wire isn't connected even though its a ground? I really don't understand how to check if the components such as the ETC, the Ignition switch and the RL are good. Do you have any instructions i could have?
im so lost
so am i supposed to leave the black wire from the CDI box unplugged while i check the other black wires? and I was wondering, could i still run the 4 wheeler if black wire isn't connected even though its a ground? I really don't understand how to check if the components such as the ETC, the Ignition switch and the RL are good. Do you have any instructions i could have? and here is a picture of my coil, I want to know if it is ground right.
leave the black wire from the CDI box unplugged and check the black wire it self on the harness side for ground and the disconnect each component in the ignition kill system to see what component stops giving a ground to the black wire
should i have the key turned over then? and what you mean by dis connect the components you mean all the wires connected to that one component?
the key does not need to be on. disconnect the connector from the ETC switch, the run stop switch and ignition switch. do it one at a time.
Alright jeff I found out which compenent was going bad, it was the ETC Unit. so what do i do now? do i have to order a new one or could it still be fixable?
did you check the thumb throttle free play?
Sorry to switch subject but I had put the positive lead of the volt meter to the battery terminal, then I had dis connected the black wire from the rest of the circuit and i put the negative lead on the black dis connnected wire the leads to the cdi box and I had no current running though my meter. Then I had put the negative lead on the opposite wire that comes from the connector on the cdi box and then I had voltage showing on my meter. I dis connected the reverse Limiter and i sitll had voltage showing and then the thumb throttle and i didn't have voltage, then I dis connected the ignition switch and then I checked the kill switch and I still had voltage. So I was wondering if you could tell me that i was reading off the "right" BLACK WIRE to check and see if the components are good. What part of the Throttle am I supposed to check to see how much play i have, Are you talking about the thumb control or actually inside the throttle itself?
the thumb control it self on the out side by pushing on the thumb throttle it self.
I checked the throttle and i measure the slack, right at 1/8 in. You didn't asnwer my other question that I asked is my last message. could you check that again please.
To top everything off I found it that last person that had the 4 wheeler had taken apart the ignition switch to drill it out, because he didn't have a key. Could it be theres no current going through the black wire from the ignition switch to the thumb throttle?
sorry about that
yes you did the test correctly
you will not have any thing through the ignition switch to the ETC switch. as the kill switches just complete a ground
so does the mean my igntion switch is bad?
so does that mean the ignition switch is bad?
the ignition switch being taken a part is not a good thing. but didn't you say the ground on the black wire to the CDI stopped when the ETC switch was disconnected?
Yes I did, thats only when the igition switch is on but when the igntion switch is off it will work. its really weird.
so their is no ground on the black wire until the ignition switch is turned to the on position. is that correct?
im guessing that yes
your guess could mean it is the ignition switch also.
so your saying that my ignition and my throttle are probably bad?
When the ignition is off and the black wire from the CDI box is dis connected, it says the throttle is ground on the black and brown wire. Then when the ignition is on, with the black wire from the CDI box still dis connected the throttle doesn't have any current on the black or brown wire when I go to check them. Does this help to explain it a little better? So what im guessing is that theres nothing wrong with the throttle, but theres something wrong with the ignition switch.
Otherwise when the ignition is on; i think that not having an actual key isnt allowing to complete the closed connection with the ground to the throttle, could this be right? or could you help me with your knowledge please. Thanks
are you checking just the black wire for ground to the CDI box on the wire harness side. when it is disconnected from the CDI box?Jeff Policky41026.1849736921
Yes, but I couldn't get anything to ground then, its like there was no juice in the system until the black wire for the igntion system
the black wire is the way the ignition spark is sloped. when any of the ignition kill switches in the system are turned on the completer the ground on the black wire to the CDI unit to stop the spark.
so maybe my CDI Box it bad?
when the black wire is disconnected from the cdi box the unit will have spark then?
if that is correct the CDI unit is OK. it would be something in the ignition kill system, like a grounded black wire from the parts in the ignition kill system throttle ETC switch, Revers limiter, ignition switch.or one of the components them selfs are bad.
alright thanks. how do you check the reverse limitier? do you only unplug the black wire? because thats a yellow/red wire, grey/orange wire and a black wire.
yes unplug the black wire to the reverse limiter and everything connected back together and that will take the reverse limiter out of the system. then see if you have spark then
ok will do, how do check the ingitition switch lol?
with the key off the black wire should have continuity to ground. with the key in the on position their should be an open to ground on the black wire.Jeff Policky41030.1601415162