Polaris cdi box problems. hey y'all have a 2009 400HO I bought from the US Embassy in Niger, Africa. Pretty frustrated that out of 4 Polaris dealers in my area, none of them know much. Promotion Predator ATV Ignition Box Repair ZTUOAUMA 61115-A01-000 0450722 0452187 A190001-02 Compatible With Polaris Predator 50 90 2003-2006 Sportsman 90 2003-2006 Scrambler 50 90 2003 Ignition CDI Box Promotion Predator ATV Ignition Box Repair ZTUOAUMA 61115-A01-000 0450722 0452187 A190001-02 Compatible With Polaris Predator 50 90 2003-2006 Sportsman 90 2003-2006 Scrambler 50 90 2003 Ignition CDI Box Attach a jumper wire from the negative battery terminal to a ground. 1998 polaris magnum 425. I was able to get a replacement and that one won’t even get it to fire bad CDI's can start to show issue's with backfiring, not idling running hot, trouble starting after warmed up, shutting off once hot and so on! Below is the wiring diagram for a 6 pin DC CDI box. Nov 8, 2025 · We will walk you through everything you need to know about your polaris phoenix cdi box. This is the same for most all of the Polaris Fuji twin cylinder engines (least in the late 80's through most of the 90's) Common Problems with CDI Polaris Wire Color Code and Ignition Systems Understanding the wire functions helps you quickly diagnose the most common problems with cdi polaris wire color code diagnostics. Whether you're So, you may be wondering why your Polaris Sportsman 500 dies when accelerating. Owner said he'd done the Polaris ignition system upgrade from the old Ducati system to the Swapping out an Ignition Coil and CDI box Polaris Sportsman 500 and similar. Is it just a coincidence that this used box went up or is there something about my sled, a short circuit or something, causing the cdi to go. The CDI (Capacitor Discharge Ignition) system is crucial for generating the spark that fires your engine, and when it fails, you'll experience hard starting, misfiring, or complete failure to start. Table of Contents What […] I have a 2001 Polaris Sportsman 500 HO, VIN: 4XACH50A41A349337, Model: AO1CH50AE, Engine S/N 0102080, with a purchase date of 10-20-2001. Once you understand the basics, it's easy to debug common problems and get your Polaris back in action. This replacement ignition box fits TRX300 and TRX400 models from 1994-2003, replacing OEM numbers 30410-HM5-505, 30410-HM5-671, 30410-HM5-672, and 30410-HM5-670. When you pull the left or right brake lever, the it revs up perfectly. However, your bike shows symptoms like ignition problems, dead cylinders, and engine stalling. 1 ) Ignition switch gone 2 ) homemade start button 3 ) wires cut spliced together The plan is After conducting these tests, it should be possible to identify and locate the problem making your CDI box malfunction. the pulser coil is in direct relation with the CDI box, if you have 0, the problem is the pulser coil. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! If only the original CDI will work, does anyone have or know where one can aquire #4060186 (except the riduclously priced new Polaris one)? Thanks in advance for your help. Same exact problem when my other box went up. '96 Xplorer 300 Aftermarket CDI box, K&N filter, jet kit, reworked expansion chamber from dirt bike, 1" taller + 1" wider rear tires, dual wenches, Rack on rear/w cargo pac, polaris box on front, Mossy Oak cover on seat, back-up lights on rear, aux. Many riders opt to repair their faulty CDI boxes rather than automatically replacing them with a new one. neither would run on it. I switched the plug wires from the box to the opposite cylinder and this time the left plug was wet and the right one dry- hence another cdi box fried. The CDI box is responsible for storing and discharging the electrical charge required to ignite the fuel-air mixture in the engine's cylinder. So my 2011 Polaris sportsman 500ho has had all the characteristics of a bad cdi box. Here are some pics. When it don't shut down I can move find someone with a 1997/1998xc7,6 or another ducati cdi and plug it in. On a 91 Polaris Indy 500, the coil & CDI are a one pc unit. This switch box replacement fits engines with 4-magnet flywheels and replaces OEM part numbers 114-5713, 855713A3, and 855713A4. It's a direct replacement for OEM numbers 3090232 and 3089238, fitting a ton of Polaris models including Hawkeye 300/400, Ranger 400/500, Scrambler 500, and Sportsman 400/500 from the early 2000s Before buying, definitely confirm this is the right part for your specific model and year, as using the wrong CDI can cause serious engine damage. There isn't much to the system, to me it seems like the stator #7 and excitor #10 are the only parts in the system. About this item Polaris ATV owners having ignition issues? This CDI box replacement might be your simple fix! Designed specifically for various Polaris models including Magnum 425/500, Sportsman 400/500, Scrambler 500, and Ranger 500 series from the late 90s to early 2000s. . So, what is the exact reason for the sportsman 500 to die when accelerating? Often, the problem is caused by a bad CDI. just keep turning over, but never fire. NO SPARK on your Polaris Sportsman? Let's troubleshoot it! Did We Fix The No Spark Issue On This Polaris ATV!? The Polaris CDI Box Wiring Diagram is a great resource for anyone who needs help with their high-tech snowmobile. Polaris ATV owners, if you're dealing with ignition issues on your Sportsman 500 or other compatible models, this CDI box will get you back on the trails! This high-performance replacement is actually better than the original OEM equipment and has been thoroughly tested before shipping. when i put it on, my pred would not start. Got a 2004 Polaris Sportsman 500 HO, think I have a bad coil and I'm not sure how to check it. FIRST STEP: BYPASS YOUR SWITCHES A very common cause of no spark is a defective ignition or kill switch. Any help is greatly appreciated. Nice job bud. i just got my new procom cdi off of ebay yesterday. Honda Fourtrax and Foreman owners, if your ATV is having ignition problems or won't start, this DC CDI box might be the solution. got it for a hundred but I did not realize that the wiring had been burgered up. I think they stole some parts to fix another bike because parts are impossible to get here. A 2008 Polaris Sportman 90 won't rev up but starts and idles fine. 6x6 Want shut off at time. I am missing a ignition coil as well as a CDI box. The CDI box in the Sportsman controls the timing, spark, rev limiter, and factory safety kill switch. popped and misfired. Cleaned the carb, changed gas, checked all the coils per the Hello all, A friend at work hooked me up with his sons 2001 sportsman 90 that he was having a problem getting started. A good polaris rzr 170 cdi problems care guide focuses on prevention. Hello all, A friend at work hooked me up with his sons 2001 sportsman 90 that he was having a problem getting started. when i put my old box back on, it ran just as good as normal. Currently, have the flywheel removed for inspection and '96 Xplorer 300 Aftermarket CDI box, K&N filter, jet kit, reworked expansion chamber from dirt bike, 1" taller + 1" wider rear tires, dual wenches, Rack on rear/w cargo pac, polaris box on front, Mossy Oak cover on seat, back-up lights on rear, aux. I have replaced the starter and battery. If you had a CDI box die on you, what were the symptoms? was anything else bad too? Did you end up replacing the box and a set of coils or the box and a new stator? When the CDI box died, did the plugs still spark a little? Was there big blue spark (usually asociated with bad coils)? Did all The truly eco-friendly polaris phoenix cdi box practice is to take your old unit to a local electronics recycling center. Below, we explore the most common signs of a failing CDI box, the underlying causes, and steps you can take to address these problems. By being aware of common issues like difficulty starting, erratic performance, and power loss, you can diagnose and address problems with your CDI box more effectively. When I began my search, I found there to be many different choices with varied timing curves. No spark issue? I’ll show you how to change a stator and a cdi on a Polaris sportsman 500. If not, check other parts of the quad. Swapping out an Ignition Coil and CDI box Polaris Sportsman 500 and similar. The 1997/1998 rmk and 1997 sks cdi/coil is the most coveted Ducati box made due to its timing curve. It happens when I go in reverse - about when the rev limiter should kick in - the engine dies. As soon as you open the throttle, the rev limiter kicks in and the engine starts popping. Learn how to properly wire a Polaris CDI box using a detailed wiring diagram. We’ll cover what it does, how to spot the signs of failure, a step-by-step testing procedure, how to replace it, and even explore the benefits of an aftermarket upgrade. Will a CDI box off a 95 ZR 580 Work on a 95 ZR 700? and what would the symptoms of a bad stator be? The problem is that it has burnt thru 3 CDI boxes since he bought it. How to bypass your switches So my 2011 Polaris sportsman 500ho has had all the characteristics of a bad cdi box. I am assuming that I need to test the resistance between the connections on the female plug. If the engine does not spark, your problem is not likely a burnt CDI. Will a CDI box off a 95 ZR 580 Work on a 95 ZR 700? and what would the symptoms of a bad stator be? CDI Pinout Diagram We’ll stick our CDI pinout diagram right here so you’ll have access to it for the steps below. Replacing it with a Polaris CDI box should fix the problem. In this article we are going to look at some of the most common Polaris Sportsman 500 problems and how you can easily troubleshoot them. I'm working my way through a "no spark" situation. I have another thread open but wanted to start a new one. Dec 17, 2025 · Understanding how to accurately diagnose a faulty CDI is paramount for efficient troubleshooting and getting the engine running smoothly again. CDI stands for Capacitor Discharge Ignition, and it is the ignition system used on the Polaris Sportsman 500. Anyone know if I So, what is the exact reason for the sportsman 500 to die when accelerating? Often, the problem is caused by a bad CDI. 🔥In this video, I reveal a simple and practical method to test a motorcycle CDI (Capacitor Discharge Ignition) unit using only a multimeter. Have tried 2 diffrententry aftermarket CDI. This article provides step-by-step instructions and helpful tips to ensure a successful installation. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! Bought an old 2002 700 Sportsman that ran and drove good. This guide outlines the symptoms and procedures necessary to determine if the CDI unit requires replacement. The reason the Polaris Sportsman 500 dies when accelerating often comes from the CDI box, which is used to pass electrical current to the spark plug and ignite the engine. I was curious if a bad cdi box would cause my bike to sputter then die at high rpms like its running out of fuel. Timing Trigger The timing trigger is responsible for sending the initial signal to the CDI Box to let it know a spark is needed. Dealing with a failing Polaris CDI box can be frustrating, but understanding the symptoms, potential causes, and troubleshooting steps can empower you to diagnose and fix the problem effectively. Alright Polaris ATV owners, if you're dealing with ignition problems, hard starting, or performance issues, this CDI box might be your solution. Ok thanks, so i should be safe in running that 99 rmk 600 cdi box, with stator in stock position, correct? I am running twin pipes, so i may even want to go with a 600 cdi box if it ends up being the problem, or should i go with the stock one for my sled? Detach and remove the CDI box so that you can test its internal circuitry separate from the rest of the ATV’s electrical system. I was able to get a replacement and that one won’t even get it to fire Ok thanks, so i should be safe in running that 99 rmk 600 cdi box, with stator in stock position, correct? I am running twin pipes, so i may even want to go with a 600 cdi box if it ends up being the problem, or should i go with the stock one for my sled? Polaris has definitely made a name for itself when it comes to producing quality ATVs however, even the best ATVs are known to experience problems overtime. Wiring can be challenging, but with the right information, you'll get it all sorted out! ️ Now let's take the next steps and get your vehicle back in top shape! If you encounter any difficulties, please feel free to reach out to me again in this chat box, and I will be happy to assist you further. Thanks. some times it will shut down other times it want. Diagnosing CDI box problems can be tricky, as symptoms often mimic other ignition system issues. This can occur due to a faulty voltage regulator, a short circuit in the electrical system, or a power surge. The CDI box is a critical component of your ATV’s ignition system, and understanding its symptoms of failure can help you maintain your vehicle's performance and longevity. It entails details about the wires, their connection points, and their functions, thereby offering a comprehensive overview of control units, ignition coils, rectifier regulators, and much more. 5 Pin Polaris CDI Wiring Diagram Below is the wiring diagram for a 5 pin CDI box. The Polaris CDI wiring diagram provides a clear, visual representation of the vehicle’s electrical system. By that I mean the first CDI box fried, and then the last 2 have melted the wires that hook up to connection #1 shown below. 1998 rmk cdi is 4060189 1997 rmk/sks is 4060144 Make sure you get one of these or eqiv. If it runs make sure you get the correct cdi back on it. How do I know if my CDI box is bad on ATV? Symptoms could include misfiring, dead cylinders, backfiring, bizarre tach behavior, and countless other things related to how your engine's running. Furthermore, choosing a high-quality replacement part that will last for years reduces waste and the environmental impact of manufacturing and shipping new parts. Observe: If the engine sparks, you have confirmed a failed CDI box on your hands. Thats the best way. Before beginning to troubleshoot ignition problems, it is best to bypass the switches. However, with a basic understanding of how a CDI box works and how to use a multimeter, you can often pinpoint the problem and save yourself time and money on unnecessary repairs. A new part Below is the wiring diagram for a 6 pin DC CDI box. thanks How do you tell if a cdi box is bad? if the sled doesnt start?? thanks The trigger tells the box to fire, the box determines when to fire which coil with the capacitors, and zap goes the spark plug, ad infinitum. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! Hi showing a CDI box not working properly and what I have to do to figure that out and fixing holes in the clutch cover Swapping out an Ignition Coil and CDI box Polaris Sportsman 500 and similar. I have a 2010 sportsman 500 ho and know someone who has a 2006 all parted out I think most parts on these bikes are the same but would like too know for sure. I also have a 2000 Polaris Sportsman 335 and that CDI box does have a 3 way connector! The chilton/haynes manual is useless when it come to finding information about this part other than - "be sure that's the problem as it is expensive to replace"geez thanks If your Polaris Scrambler 500 is having ignition issues or just won't start, this Caltric CDI module might be your solution! This is a direct replacement part specifically designed for 2000-2002 Scrambler 500 models (for 2000, you'll need serial number 00-04730 or later). NO SPARK on your Polaris Sportsman? Let's troubleshoot it! Did We Fix The No Spark Issue On This Polaris ATV!? Wondering what years are compatible for cdi boxes. We have checked and rechecked the system and after replacing with the known good component from my '99 SKS we varifed the diagnosis. The only way to get it back running is to disconnect the black "kill" wire and restart the engine My son's stock '98 600 RMK needs a replacement CDI module. To bypass your CDI box, you clear your bench, remove the box, check resistance specifications, measure the primary and secondary oil resistance, and compare readings. Can A Bad CDI Cause No Spark? A bad CDI box may not cause a spark at all. 6 Pin Polaris AC CDI Wiring Diagram Below is the wiring diagram for a 6 pin AC CDI box. Jan 26, 2020 · What I would do is disconnect the black wire at the CDI unit and use a jumper wire to connect it to ground - if it dies using a jumper wire then the problem is wiring - if it wont die with a jumper wire, then the problem is internal to the CDI unit. I have a 2000 Polaris magnum 500 that I've replaced the CDI box in twice now and it just "blew" again. There are several potential causes for a CDI box to go bad: Electrical Overload: Excessive voltage or current can damage the CDI box. Jan 26, 2026 · This guide provides a step-by-step approach to checking a CDI box with a multimeter, empowering you to diagnose ignition problems, save money on repairs, and gain a deeper understanding of how your engine works. This WFLNHB CDI box is a direct replacement for part number 3087169 and fits multiple Polaris models including Sportsman 500 HO from 2002-2004, Sportsman 400, Magnum 500, Scrambler 500, and several other Polaris ATVs from those model years. While CDIs are solid-state electronics that eventually fail, you can extend their life and prevent premature failure with a few simple checks. 1 ) Ignition switch gone 2 ) homemade start button 3 ) wires cut spliced together The plan is If a CDI box goes bad, it can lead to various issues and problems with the motorcycle's performance. The only parts available here would be for yamaha DT 125cc. Check at your stator plate if you have a bad connection or something like that. Upon opening the CDI box, you will find a motherboard circuit that carries capacitors, resistors, fuses, and wires. One is of the CDI Ignition Box, the others are of the connectors on the stator cable. Can anyone tell me how? My problem is not the sparkbplug test because I use 3 different way to test for spark all 3 type just give one spark and no spark after my problem I don't know how to test the cdi box Swapping out an Ignition Coil and CDI box Polaris Sportsman 500 and similar. MY PROBLEM IS NOT GROUND it's the blue and white wire intering CDI box. Grab your multimeter, set it to measure resistance in Ohms and place a probe on each side of the CDI’s terminal plug to complete the circuit. Got questions for us? Ask them here! I also have a 2000 Polaris Sportsman 335 and that CDI box does have a 3 way connector! The chilton/haynes manual is useless when it come to finding information about this part other than - "be sure that's the problem as it is expensive to replace"geez thanks The trigger tells the box to fire, the box determines when to fire which coil with the capacitors, and zap goes the spark plug, ad infinitum. What am i doing wrong? any help would be great. If your Sportsman has been acting up electrically and you've ruled out simpler issues like spark plugs or coil problems, this CDI replacement could get you back on the trails. kzo6i, rgg7, hmqy, vo0bh, damj, 6easn, nki9, mhq0j, p5col, v5isqf,