2005 polaris Phoenix 200 elec no crank no start troubleshooting + preformace tuning

[baller74]

Hi here's the other half of the awesome deal on a quad! 

grumbles when I went to look at this quad the seat was off and the headlight was laying aside the tank. first things I noticed  was the wiring or wires that were cut to the cdi box and the ignition switch also the seat was  off and the fuse off the battery was removed  next was the jumper  cables hooked up directly to the 110v house plug and the smell of burnt plastic and wire permitted the area. the guy selling it wasin a pinch and eeded quick cash so I overlooked my gut instinct and did a quick tally of cost and parts if I had tobuy the whole  electrical system  essentials to make it run again and slowly let the numbers 50 fly out and shut up. the foot crank was stripping bolt snapped  but I turned it over  good compression . this quad was clean as a whistle like brandnew  andthe harness so far is in excellent shape. I stopped at a friend's house and found a kymko cdi since box was actually the maker of this engine. fo free and began my next days adventures dreaming that the wind would be in my face and the cops at my back way behind me hauling as* round town In a couple hours I mean he said it ran just fine the day before ....

 

well it's 715  this evening and I'm still trying to find a factory service manual that is free I can download at least the electrical schematis and conponant pinouts with wire color  and a troubleshoot guide with component testing procedures as there more than six wires for the cdi the leftovers are green green with yellow   babyblue and brown with yellow  no eof these are hooked up and she's a dead horse hoping someone could walk me threw them and there correct designation not just spliced I to a hit etc. the wires I hooked to the cdu are white pickup pin 1, blackwhite the pin 2, blackgreen ground pin 3  4 empty  2 plug  slot 1 empty slot 2 brownyellow power. now no been arguing with crapgpt all day sYs the 2 plug 6 wire ac cdi is the oem match for this one. now there was t a cdi when I bought it was "lost" probly along with the "KEY" but the cdi I pulled up shaws a 2 wire boobs 2pluh 6 pin cdi need to know if I can make her go with this cdi I looked at the wiring to that one And shows the stator hot and cold go to those extras  not sure but I am leaning towRd there's N internal voltage regulator built into that cdi box. anyone have the skinny on this I have  a voltage regulator 5 wire from another bike new bit has a pink wire when I put jumpers from my jeep to the battery and fused the hot side up  and tied the red and brown side on it switch no get nada but have voltage from battery to start solenoid  to the cdi hot pin the main harness connectors the headlights the green with yellow and  all the red wires read that brown with yellow is an accessory wire 12v switched used for engine control restrictions  but won't run without constant 12v if this is true I want it bypassed I. 205 pounds and little 200 is gonna struggle enough hauling me don't need any extra help there and infact if anyone can give me a few parts number to buy for some extra preformace and horsepower. I'm on a beer budget after my superchargered wrangler build so pheniox racing gurus and backwood tweeker brothers your input will be invaluable but you would add what you know. alright guy let er ripp I'm all ears.

[davefrombc]

There is a posting of a service manual in  the downloads section of QuadCrazy

[baller74]

thank you i just foun$ it appreciated the direcrion to find it.

[Gwbarm]

You have been bust and really done your homework. From what i can gather from your post, a lot to take in, i dont think you can make it right with your existing CDI box. Im assuming with the CDI wires  all cut by someone else, he has already tried that. Its possible you may be able to get spark from it, but the CDI box also controls other things such as timing and is hooked in with other safety features in the electrical system. Im just hoping you caan get it back right with the correct CDI but if all the wires are chopped with correct harness plugs missing you may need another harness. If it is as nice as you say i would want to get it back to as close to factory as possible. Im not that up on Polaris wire colors for wiring but i have tried to do what you are doing before and it never comes works out perfectly. It may run but can never really get full performance out of it.