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I am working on a 1997 Polaris Trailboss 250 2 stroke. The owner stated the transmission locked up and he fixed it (I don't know how) he took it for a test drive and everything ran fine. He went three days later and it started and idled but when he added throttle it would back fire through the carburetor. I took the carbureator apart checked the needle valves cleaned everything up blew it out and put it back and it did the same thing. When I pressed the yellow override reverse button it ran fine for a while then would bog down. Could the CDI unit be bad? The owner is an auto mechanic and he states it sounds like it is out of time. I did find timing marks on the fly wheel but the only way it would be out of time is if the stator may be bad? Before I start doing some unnecessary tear down I thought I would try this web site. I am a certified master technician in small engine repair but not familar with this product. Thanks

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Posted on Jan 02, 2017

  • 16 Answers

SOURCE: Brake fluid for a '91 Polaris Trailboss ATV

you dont need to check it just make sure that when u change the fluid that you fill it up to the top.

Posted on Jul 24, 2009

  • 1 Answer

SOURCE: Polaris 1999 Sportsman 500. Had no fire. Replaced

I had a similar problem and it turned out to be 2 problems, a bad ground connector and a weak battery. Hope this helps! In trying to repair it though, I nicked a wire on the stator. Do you have a spare for sale?

Posted on Dec 05, 2009

Testimonial: "Replaced Voltage Regulator. Still no spark. Ordered another CDI, #4 I believe. Each wire will be checked. Stator? Email me Mike@RenegadeArtifacts.Com"

  • 2030 Answers

SOURCE: My polaris Predator 500 2005. it blew a rubber

if its a valve cover gasket that blew like that you could have major problems

Could be that it leaned aout and burnt up a cylnder or a piston, and you have major blow by now.

Posted on Jan 12, 2010

  • 18 Answers

SOURCE: i have changed my stator and cdi box on a 1999

According to my polaris manual, is says'' The regulator / rectifier is tested by process of elimination ( when all other possable causesof chargingsystem failurehave been checkedand eliminated, the rectifier is defective). I had to replace my stator and then had a simular problem as you have and it was that the ignition pulse coil wasn't properly guaged ( sometimes the metal retainer will allow slight movement) You might want to also check the coil resistance 0.3 to 0.5 ohms the coil secondary resistance spark plug cap installed 11,300 ohms spark plug cap removed6300 ohms. Hope this helps out. Good luck

Posted on Mar 27, 2010

  • 5 Answers

SOURCE: I have a 1996 polaris

same thing happend with my polaris all u have to do is unplug where the override goes to and unplug it

Posted on Aug 31, 2010

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