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  1. #1

    Polaris hurricane no spark

    Hello, i am new member here and need some help with my polaris hurricane 700 1996. Bought this machine with spark problem. There is zero spark. Last owner said that he changed stator, but didint get the spark back. So i read some posts about the problem and made some tests. Checked the red-purple wire and its good 12v. So i have power on CDI? Then checked the brown wire which is coming from stator to cdi while starting the engine and i was 4v but should be 9v? But there is a black (mass?) wire coming from cdi and if i put it on mass then there was 0v on brown wire while cranking engine. And i spotted some broken wires that i dont know where are they going, ill post picture about it. Maybe last owner connected some wires wrong or something is broken. What should i look next? Battery is good, but ill going to try with another battery too.

    Thanks
    Valter
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  2. #2
    Click avatar for tech links/info K447's Avatar
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    Welcome

    Click on my signature link, then have a look for the links and info about wiring diagrams.

    Unless all the wires are properly connected, the machine is not going to work. The Terminal board has markings for wire color coding. The black wires provide grounding, and also link the grounds for several sections together.

    Tip: The Polaris carburetor ignition modules for the red engines need a really strong battery, or you will not have spark. Even if everything else is correct.

    Note: There are two different ignition systems. The original Gen 1 CDI + stator, and the much more reliable Gen III (there is also a Gen II). Gen 1 stators are a known failure item. Gen 3 stator can not be used with Gen 1 CDI.

    The normal ‘upgrade’ is to replace the original stator and CDI with Gen III. Polaris used to sell an ignition upgrade kit. The genuine Polaris upgrade kit is no longer available.

    SBT does sell an ignition upgrade kit, with a genuine PVL (same as Polaris OEM) CDI - these CDI work just fine.

    But the SBT supplied stator (as far as I know) is not PVL sourced. There have been multiple reports that some of the aftermarket stators do not work properly. Inconsistent, as other people have reported their aftermarket stator does work. Might be manufacturing variables?

  3. #3
    casey67's Avatar
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    https://sites.google.com/site/polpwc...lpwcman%2Fhome

    As K447 stated,the battery is extremely important. It must have over 10.6v WHILE cranking for the CDI to work at all.
    You need to test that and report back the exact result.

    The black wire with eyelet is the main ground for the CDI, it has to be grounded as well as the same eyelet coming from the Stator- its very important to find that wire.

    Get a clear picture of the stator wires.(next to the CDI wires. The Chinese stators ususally had kinda faded color to their wires.

    The circuit breaker is missing-the red wire coming from the red cable on starter relay should go to the 15amp circuit breaker.
    Other side of circuit breaker will be the red/pur wire that the stator harness connects to-then jumps over to the CDI connecter-then the red/pur on terminal board.
    Does look as if the red/pur goes to an inline fuse ??

    The blue wire you have in your hand does not look like Polaris wiring. It looks to originate where the "trim" wiring would go. Of course the Hurricane does not have trim.
    The wire bundle looks as if it might be from the Bilge pump ? But would be org/blk and black wires.

  4. #4
    Thanks for the help, i will go and make the tests and better pictures some day and posts it here.

  5. #5
    So tested with good and new Lithium battery which had 12v while cranking the engine and still no spark. What should look next?
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  6. #6
    Tested the brown wire while cranking and it was like 0.20volts. Disconnected black wire which is coming from cdi to ground and then tested brown wire. It showd 4-5volts then. Two black/white wires are going to ignition, one had 5-6volts other had 0volts.

  7. #7
    casey67's Avatar
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    Quote Originally Posted by casey67 View Post
    https://sites.google.com/site/polpwc...lpwcman%2Fhome

    As K447 stated,the battery is extremely important. It must have over 10.6v WHILE cranking for the CDI to work at all.
    You need to test that and report back the exact result.

    The black wire with eyelet is the main ground for the CDI, it has to be grounded as well as the same eyelet coming from the Stator- its very important to find that wire.

    Get a clear picture of the stator wires.(next to the CDI wires. The Chinese stators ususally had kinda faded color to their wires.

    The circuit breaker is missing-the red wire coming from the red cable on starter relay should go to the 15amp circuit breaker.
    Other side of circuit breaker will be the red/pur wire that the stator harness connects to-then jumps over to the CDI connecter-then the red/pur on terminal board.
    Does look as if the red/pur goes to an inline fuse ??

    The blue wire you have in your hand does not look like Polaris wiring. It looks to originate where the "trim" wiring would go. Of course the Hurricane does not have trim.
    The wire bundle looks as if it might be from the Bilge pump ? But would be org/blk and black wires.
    Pretty sure they don't make "Lithium" batteries for these.

    We need the exact reading on CDI red/pur wire.(red/pur= red with purple stripe)

    You have modified wiring-you need to make sure the wires I mentioned are correct for anything to work.

  8. #8
    So tested red/pur wire 13volts and while cranking it was around 10. The black wire coming from cdi i asked for, i put that mass and the voltage on brown wire dropped from 4v to 0,10-0.20v while cranking. The brown wire is coming from stator to cdi and i read from internet that the brown wire should be around 9volts while cranking. Theres 2 fuses ill make picture from that. Seems like somebody have modified the electric system.

  9. #9
    casey67's Avatar
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    Quote Originally Posted by Valter View Post
    So tested red/pur wire 13volts and while cranking it was around 10. The black wire coming from cdi
    10v is not enough. The CDI DOES NOT work with less then 10.6 , guaranteed. These ignition systems need a very strong battery/a perfect battery. Cheap/old/weak batteries will not work.

    As all DC electrical items need a + wire and a - wire to operate at all. The red/pur is the + wire. The black with eyelet is the -. It has to be grounded. In the picture you have it separate from the other black wires, keep them together.
    As I had said, there should be another black wire with eyelet from the stator . Find that wire and put it with the CDI wire.

  10. #10
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