88' Indy 400 weak spark issue
I'm hoping you tech guys can help me.
(I did some searching but could only find this issue discussed on sleds like the tripples with seperate ign coils.)
I started my 88' Polaris Indy 400 up to put it away last year on a 50 degree day (it's jetted for 30 & colder) with zero issues, walked away from it & left it idling for a couple minutes to warm up. After those couple minutes it stalled.
Thinking nothing of it (figured it was just running rich since it was so warm), I went over to restart it. After trying new plugs, some ether, and breaking the pull cord - I never got it to even try to fire and could not see any spark getting to the plugs when grounded to the head (while pulling it so I wasn't exactly close to the plugs) - so I put it away for the summer & said the heck with it.
Now I'm trying to get it running again.
The FUJI twins have a CDI with integrated coil from what I've read, my original CDI looked like crud, & at the time it stalled I couldn't see any spark while pulling, so I bought another CDI used - this one turned out to be the wrong mounting and plug, but the wires were all the same colors so I wired in the plug off the old one so I could at least test it.
After fixing the pull starter last night I tried starting it with the "new" CDI unit - it still didn't start even with ether. So I had my Fiance watch the grounded plugs as I pulled it over. She said she could see a tiny blue spark on both plugs - after having her pull it so I could confirm this I went back to the book.
Using the books specs I tested the exciter coil, pulser coil and connections and all those resistances seemed to spec out correct or very close anyway (my anolog meter doesn't read super accurately)
So my questions are ;
- did Polaris ever change those wire colors routing, meaning I could have the CDI wired incorrectly onto the original plug?
- what could cause the CDI to not put out enough spark?
- could the flywheel magnets all of a sudden go weak?
- could the exciter/pulser coils spec out right but still not put out enough voltage to fill the capacitor for maximum spark & can you test that?
- could the spark plug wire "caps" have both failed at the same time restricting spark to both plugs?
- could my voltage regulator have failed causing a lack of CDI input voltage & if so where is it (I had assumed the voltage regulator was only related to the lighting coil circuit)?
- is there a possible failed link in this system I'm missing?
- any other ideas?
Thanks in advance.
1988 Polaris Indy 400 - sold
1996 Polaris Indy 500 - sold
01' XC 700 SP - YeeHaw!!!
01' XC 500 - currently having a couple issues.