Thread: Polaris CDI Jumper Wire TSB
08-21-2006, 01:54 PM #1
Polaris CDI Jumper Wire TSB
Service Bulletin # PWC-00-05
August 8, 2000
Add Jumper Wire to CDI
Model Affected: Serial Number Range:
2000 Virage (W005197D) ALL
2000 Virage TX (W005199D) ALL
2000 Pro 1200 (W004999D) ALL
2000 Genesis (W005099D) ALL
SCENARIO #1 MODELS WITH DUAL FUNCTION START/STOP BUTTON
Symptom: Engine will not turn over when engine is warm. After stopping the engine and trying
to re-start the engine when warm, the starter motor will not turn over. In this scenario, the CDI
remains powered up after the engine is shut off, causing the CDI to think the engine is still run-ning
even though it is not. After the engine and CDI cool, it will re-start normally. Install jumper
wire PN 2460928 to resolve this issue, following the instructions below.
SCENARIO #2 MODELS WITH SEPARATE START/STOP BUTTON
Symptom: Engine turns over but will not start when engine is warm. After stopping the engine
and trying to re-start the engine when warm, the engine will crank, but not start. Again, in this
scenario, the CDI remains powered up after the engine is shut off, causing the CDI to think the
engine is still running even though it is not. After the engine and CDI cool, it will re-start normally.
Install jumper wire PN 2460928 to resolve this issue, following the instructions below.
Part No. Description
1 2460928 Harness, Jumper, PWC
1. Disconnect the NEGATIVE (-) battery cable from
2. Open electrical box.
3. Disconnect RED/PURPLE wire from CDI box.
4. Clean the FEMALE end of the RED/PURPLE wire,
disconnected in the previous step and apply electri-cal
tape to seal the open end. Tuck the FEMALE
end of the RED/PURPLE wire under the CDI box.
RED/PURPLE wire from CDI
PWC-00-05 Page 2 of 2
1. Install the RED/PURPLE end of the jumper wire,
PN2460928, on to RED/PURPLE MALEconnector
from the CDI box.
2. Install the open ORANGE connector end to the
open ORANGE spade on the terminal board.
1. Once the jumper wire is connected, carefully pack
the wires inside the electrical box cover, making
sure that wires are not kinked or damaged on any
internal component. Install the electrical box on the
mounting plate and lock the latches.
Wrap with electrical tape,
tuck under CDI
jumper wire to RED/
PURPLE male connec-tor
from CDI box.
Connect open ORANGE end to the
ORANGE spade connector on the
2. Reconnect the NEGATIVE (-) battery cable to the
NEGATIVE battery terminal.
Please perform this Service Bulletin on all affected units in your inventory. Contact owners of delivered
units immediately and make arrangements to perform this warranty repair.
POLARIS SALES INC.
Craig M. Wilfahrt
Manager, Service/Technical Training
08-21-2006, 06:07 PM #2
i didn't realize there was a service bulletin on this,scenario one is exactly what happen to my virage and on a hunch i cut the connect and used the left over wire to make a jumper,worked perfect
08-22-2006, 12:48 PM #3
LOL Doug dude, we've been poasting this update for years, where you been??
08-22-2006, 01:04 PM #4
Yeah I was going to say that too but with the boards getting dumped a few times and many old postings lost, I can see how it could have been missed.
08-22-2006, 01:24 PM #5
Well I'll give Dougie the benefit of the doubt BUT I've posted it no less than a dozen times over the last month. LOLC'mon Doug you just messin' with us??
08-23-2006, 10:07 PM #6
it happened last year and i got the idea of something you posted i think al
06-02-2010, 09:30 AM #7
- Join Date
- May 2010
- Dallas, TX
1). Does anyone have any photos to support this procedure?
2). In reference to Step 2 of the procedure above, how can I make the jumper wire without having to order one? Is it simply a loop through a female spade with an orange wire and female spade coming out of it?
06-02-2010, 05:53 PM #8
There will only be a couple wires that go from one side of the box to the other. Find the red/purple stripe wire from the CDI .Trace it to the terminal board. Is it attached to terminals marked red/pur.( If it is attached to other red/pur wires that lead to the terminal board-also means it has not been done) Or does it go to the "org" terminals. Orange terminals are switched on when running, off when shut off. That is what helps the CDI work properly
If you need to make a jumper wire. One end needs to have a round ( barrel type) connecter (Female) . Other end will need to be a flat ( spade type) connecter ,( also female)
06-03-2010, 10:11 AM #9
- Join Date
- Jul 2007
- Cedar Rapids,Iowa
08-30-2010, 01:18 PM #10
- Join Date
- Jul 2007
- near Toronto, Canada
How to do Service Bulletin PWC-00-05 (CDI Red/Purple to Orange) Fix no-warm-restartPolaris CDI Jumper Wire TSB
Service Bulletin # PWC-00-05...
All red domestic carburetor engines can have this change applied. After about the 2000 model year, they came from the factory in this configuration.
This change applies primarily to 1996-2000 red engines, with or without the Ignition System Update Kit installed.
Working through the process
1. Disconnect the NEGATIVE (-) battery cable from the battery.
2. Open electrical box.
3. Disconnect/unplug RED/PURPLE wire that goes directly into the CDI module.
That would be the circled connection in this photo.
Pull the CDI Red/Purple bullet connector out of the Y split connection.
Leave the remaining Red/Purple wires where they are
4. Clean the FEMALE end of the RED/PURPLE wire (that would be the Y split connector) disconnected in the previous step and apply electrical tape to seal the open end. Tuck the FEMALE end of the RED/PURPLE wire under the CDI box.
At this point the RED/PURPLE wire from CDI is all by itself, connected to nothing.
All other Red/Purple wires remain connected to the Red/Purple terminals.
5. Now you can do the next step one of two ways.
A) The easy method is to cut the male bullet connector off the end of the CDI Red/Purple wire, then attach an insulated crimp-on female spade connector.
Make sure the resulting CDI wire will be long enough to reach the Orange terminal. If not, you can use a butt connector to extend the wire, or use method B below.
Plug the newly attached crimp connector onto one of the Orange terminals.
B) The other method is what the jumper wire in 2460928 does.6. Once the jumper wire is connected, carefully pack the wires inside the electrical box cover, making sure that wires are not kinked or damaged on any internal component.
Purchase a female insulated spade connector, as above, and also a female Bullet connector that will mate with the original CDI bullet connector. Both parts must be of the fully insulated type.
Find a short section of stranded wire (Orange would be ideal, but any color will do) of reasonable wire gauge, and crimp the connectors onto each end. Plug one end into the CDI Bullet connector. Make sure it is fully insulated, and wrap tape or heat shrink sleeve around it to make sure it stays together, and cannot short to anything else.
Plug the other end (female spade connector) onto an Orange terminal.
Install the electrical box on the mounting plate and lock the latches.
7. Reconnect the NEGATIVE (-) battery cable to the NEGATIVE battery terminal.
Last edited by K447; 03-27-2011 at 09:32 PM.
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