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2002 POLARIS 325 MAGNUM 4X4 NO SPARK ISSUE COIL SWAP NO SPARK RUN SWITCH SWAP NO SPARK GAP AT THROTTLE SWITCH NO SPARK TRANS SWITCHES SWAP STILL NO SPARK FUSES ANYWHERE? NEED HELP

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  • dgdoubledwel Aug 30, 2010

    CHECKED RED/WHITE WIRE AT BACK OF IGNITION SWITCH. HOT WHEN KEY IS ON. ENGINE IS NOT SAGGING ON CLUTCH. CHECKED YELLOW AND GREEN WIRES 4 POWER WHEN CRANKING MOTOR OVER...THEY ARE HOT. UNHOOKED FROM BLACK WIRE AT CDI STILL NOSPARK. CDI TROUBLE????

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  • Master
  • 2,272 Answers

You need to look at the wiring block. Check for 12v source at the red/white wires with the key switch on. The red/white wires are always hot with the key on. If not check your key switch.the quick connect at the kill switch/reverse override box .Also check the power to spark plugs.The spark plugs get power from coils to spark.If there is no power to spark plugs and coils are ok then its faulty spark plugs it self or faulty connection between spark plug to coil pack. try unplugging the black wire from the CDI .Then check.If still no spark then its faulty cdi.Get it checked. Also check if there is gap got created between between the floorboard and the clutch cover . the covers sometimes will sag or melt a bit and get against the drive clutch or the transmission pulley.
causing it to drag when you try to start it. that could be the problem.
also look for any wires that may be resting against the cover.
you may have a short that makes contact and by moving the cover you move the wire.
the clutch runs independantly of the transmission.
once you give it gas the engine spins faster and the clutch draws in tight against the belt causing the transmission to turn.

the clutch and the crank are balanced together.

you could yank the cover and make sure there is no visible damage to the clutch itself.
Also check the motor mounts.They aren't very large and wear out easily letting the engine sag and could cause it to get against the clutch cover.But also because moving the cover moves the engine a littls it could be a loose connection.If it starts by lifting the cover, get down and lift the cover and look to see what is moving around the engine when it moves. check all of your wire connections. The other thing to check is,that check that fuel is flowing freely and running properly through the pump.If its low if no fuel running to the pump then its the cause of faulty fuel pump or fuel blockage.Get it checked and cleared.
Thanks. Keep updated for any more query. You can rate this solution and show your appreciation.

Posted on Aug 30, 2010

  • raj somaiya
    raj somaiya Aug 30, 2010

    Then is possible that cdi is faulty and needs to be replaced.Its causing the problem.As most of the possibilities are checked ok or replaced by you.And the cdi is left causing this problem mostly.
    Thanks for keeping updated With you query.

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