Frank Angerano

Ok so that eliminates the stator. I’m surprised that one wire brings the cdi and the rest of the system together. Find that wire coming from the on off button disconnect and see what happens. I’m still hoping it’s just a mater of an oem reg/rectifier that’s causing all this.

Hey Gary, I was looking through your wiring diagram and highlighted a few things. Please verify that I’m looking at the right diagram please. As a side note have you tested your stator coil to see that it’s not dead shorted. Reason I’m asking is based on your wiring diagram it looks as the stator goes directly to the regulator/rectifier. So I would unplug the stator and do a quick test from each phase to ground and see if you get any sort of continuity on the tester. You shouldn’t get any reading from any of them yellow wires to ground. If so there a problem within the stator. You can also unplug the stator and try the regulator again and see if it blows a fuse. Then if that checks out ok I would disconnect the battery and put one lead of the tester to the ground and start touching various parts of the red (hot wire) that comes from the fuse block going to the regulator as well as other areas that carry a 12v hot lead looking for a short. So make sure your tester is on continuity/ohms setting. I like to use a tester that beeps when there is continuity. Also test the starter wire, starter relay and the line going back to the battery to ground for continuity. This way you eliminated everything that could be a short leaving only a fault in the cdi. lastly the third pic I circled the on off switch in blue it appears the wire is listed as “P” so maybe (purple?) it comes from the on/off switch and if it’s disconnected it appears it will isolate the cdi unit from the rest of the system. So try to find that wire around the kill switch and unplug it. Install the new rectifier and see if the fuse pops. Im in and out of WiFi so if I don’t get back right away I’m out of range. Let me know. good luck

What’s up Eric and welcome to Quadcrazy! There’s always people looking for other people to ride in the areas you live In and many other areas as well. Check out some of the local clubs. Click on the top right side of the page drop down menu. Go to the clubs and click. Have a look. I think there is an NC club. Aside from that good luck with the new bike and be sure to post some pictures. Ride safe!

Good morning from da islands man!

Welcome to Quadcrazy @Monika Novakov I’m not sure what you mean by the generator/starter ? Do you mean the left side engine cover? The starter should be removable with a little bit of wiggling without taking that cover off. You can remove the left side engine cover to see what’s going on with the bendix/one way clutch depending on the year/model and see how it’s all operating and if anything is wrong. If the cover is sticking maybe a little tap with a rubber mallet will help. Here’s a YouTube video of a 250. Should be pretty much the same.

Why can’t you remove the old cable from the old cap ? Under the boot should be a metal bent piece than unscrews from the cap? At least that’s what I remember. I’m sure you probably checked it out but for some reason I thought that piece came off of the cap of the carburetor.

That’s a good piece of change to pick up for stuff laying around. We have all the same stuff here and now as well as the electronics like TVs etc, we are entering an age of where we will have to pay 10 cents per plastic bag at the supermarket now starting September here.

Nice work kiddo. Ok going to loose WiFi again. Be back later.

This is a big thing here in my state with batteries now they charge you to take the old one away it’s a recycling fee. The same has happened with the tires now. You get a tire change they charge you $5 bucks a tire for recycling now.

Your right @davefrombc I didn’t word that correctly jumping from a car is the point I wanted to get across. I agree the voltage is the same but the regulated amount of voltage could change going to the pump since a higher cca battery can throw the regulator and any other components on an atv into a tailspin if you would. This is why stator coils burn can burn up as well when jumped from a car. So yes I agree if it were a stand alone battery it would be ok.

Have you gotten the nut off of the clutch shaft? The best thing I would say is let it sit for a few hours with penetrating oil. Then take a torch and warm it up. NO CRAZY HEAT! Just enough to expand the metal. If nothing else works you may have to get a wheel puller and grab it. Keep in mind the torch used the wrong way could burn up seals. So be careful.

Welcome to Quadcrazy @Jade Dockery You will find tons of helpful info here as well as juts some cool posts of members doing some cool stuff. So even after the bikes are ready to roll we love to see pics of everyone having fun. So ask away post as many pics as you need and remember the only stupid question is the question that’s not asked.

Welcome to Quadcrazy, chances are unless you see burnt or melted wiring then the harness is probably fine. The only way one would burn up a harness is by installing a battery in backwards. Very possible but it’s a far and few thing to see. But even at that most of the time it’s a fuseable link or main fuse that goes. We have had plenty of bayous come thru here in a past few months and all were salvageable and the outcome was good. Including one of mine. I picked one up where the previous owner said the same thing. Big electrical problems. Turned out it was a safety switch that was bad. So get familiar with the bike, take some of the basic stuff off to expose some of the wiring and start looking for anything burnt. My guess is it will be the usual suspect which is the (neural safety switch) or a faulty kill switch. Order a new battery if needed and try to avoid jumping it with a car or a crazy strong jumper pack. The bike looks great otherwise so for the price 🤭hey you cant complain! The plastics alone are worth a few hundred bucks if the bike was beyond repair.

When you jumped the bike what do you use to jump it ? If you use a car battery the amperage is extremely high for something like that. You can cause damage to the pump. Aside from that that if it were another atv you jumped it with then I would check all the gaskets on the pump , it’s possibly a defective pump.

Ok that would make sense. I was wondering about maybe possibly spacer. But did the spacer come with it ? Also how thick was the spacer ? I know that the shaft coming out of the throttle body is only so long? Lastly did the new sensor have any paper work that mentions anything about the spacer? I would reach out to the Polaris via email and let them know about this problem and the aggravation it’s caused. Pain and suffering damages of not being able to ride!!!!! Lol. Nice work brother, ride safe.

Hey Tyler welcome to Quadcrazy. So your having shifting problems on the bayou and you changed friction and steel plates? I’m a little confused. What parts exactly did you change? There’s also a centrifugal clutch inside the right side engine cover that’s part of the clutching system. When you opened the cover did you inspect that clutch? Also how as the engine oil? Have you changed it and looked for any metal shavings inside the oil?

Is the head of the engine painted or the entire engine painted ? A lot of people paint the head or engine trapping in heat which causes a overheating problem. Check the exhaust that its clear and not packed with sh** causing to much back pressure. Lastly is an engine covered in mud or excessive dirt build. These things add up and cause excessive heat along with a hotter plug and even a high octane fuel cause this condition. I would wash the engine down good. If the engine is painted then a pressure wash may be in order.

Great job Mike. Keep us posted. Ride safe!

That is a good dealer and to be honest it’s worth the money to drop it off and not worry about tearing it apart yourself if you can trust someone and it sounds like you have a trustworthy guy. Did you have to rejet the carb due to the bore? As far as the rubbing wires I’ve come across that. Right around the front end of the frame where the harness is against the frame due to turning. I also feel bikes with plows generally have a greater amount of wear and tear on not only the front end but the engine as well. So additional maintenance is required. You have machines with high mileage on them. It’s great to see bikes go that long and it’s great to see the upkeep that you and some of the other members here do. You also do a lot of the poker runs it sounds fun and we would like to join you on one of them so keep me posted if you don’t mind us joining you for a day. Minus the mud hole 🥴! Myself I like to do the engine work and have taught my son along the way so that’s been fun. We recently picked up a really nice snow blower that was left behind on a house I was renovating, practically new but left full of old gas. So I pulled the carburetor off and handed it to my son, 30 min later it was rebuilt and back on the blower running like a champ. He is 15 and well versed on gas engines and tearing them down and rebuilding etc. I want him to know how to do this sort of stuff. We always get into something with a motor and always looking to pick up an older bike to fix up or work on to keep us busy while we keep our newer machines maintained and always doing upgrades. Keep up the good posts and great input and photos you always provide brother.

Good morning Quadcrazians! One more day to vacation ! 🏝 Happy Sunday!

Your welcome mike. But are you sure it’s the switch ? It would suck for you if you wasted time and money on the switch if it’s not bad. I was only pointing you in possible directions of what the problem could be. So unless you positively identified that as a problem you may be disappointed when you install it. I just want to throw that out there brother. Like @JacobSlabach said maybe a kill switch etc ? You can do some testing before buying parts to positively diagnose the problem. Just want to let you know.

Hey Ben welcome to Quadcrazy! You have come to the right place. You will find all the help you need here.

I think your right but there should be a lock out of some sort ? I have to take a second look at the diagram. I would be surprised that it would be able to start in gear.

I was talking about the neutral safety switch but as always @JacobSlabach you bring good direction to the table! The Polaris guy!

No what you needed is the right relay. The plug you can use steak on connectors for the relay. You need to order the right oem relay and the plug if possible but not necessary!