I replaced my 400 single seat with a dual seat/backrest. Local repair guy said the brake light sending unit was failing, and that he had a unit I could use, but required me to actually cut the wires and then add female connectors so they'd mate to the male connectors on the replacement unit.
The brake light worked for a while, but at the end of this '16 season I noticed it wouldn't start up anymore. I let it sit a few months, then pulled one of the plugs with the wire attached and definitely saw no spark. I even held the spark plug to the cylinder head to see if that would change anything, but didn't.
Any recommendations on root cause? Would it be the CDI ignition assembly, the stator, the regulator, other? Could my rigging of that brake light switch have caused one of the electrical units to fail?
My manual 15335026-Polaris_Download_1985_1995_Snowmobile_Service_Manu al_Repair.pdf gave me the following:
- Spark plug(s) fouled (can't be; new plugs/checked clean)
- Secondary coil bad or wires disconnected (not sure on this one)
- Primary coil shorted or open (how to check?)
- Ignition points pitted or dirty (how to check?)
- Ignition switch shorted (how to check?)
- Auxiliary switch (how to check?)
I do have a current tester with the pointed end, light and clamp. I also have an Actron CP7672 AC & DC voltmeter with the red/black leads.
All the lights, displays, and even hand warmers worked fine.
Attached is a schematic screen shot.
Thanks, Eric in Slinger, WI.
90 Polaris 400 - no spark