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  1. #1

    Intermitent spark with upgrade

    Greets:

    I recently upgraded a '97 SLTX ignition system, (Polaris Upgrade Kit Part #2873091, Stator/CDI), and installed a new battery...

    ==========================

    After numerous tries, it has only started/idled two times.

    There is no spark each time I check.....

    Grounds, voltages and continuities at the respective wires inside the electrical box are verified good, kill switch, and limiter both removed to test.

    Plugs are new, Plug wires seem good.

    ==========================

    I understand that ignition coils rarely go bad, and wonder if the new CDI is bad out of the box...

    ==========================

    Any ideas that might help will be greatly appreciated..

    Ty,

    Rich


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Have you;

    Removed and cleaned both ends of both heavy battery cables?

    Made sure the negative cable attachment to the engine block is clean metal-to-metal contact?

    Measured the voltage right at the CDI Red/Purple wire while cranking?

    Ohm checked the ignition coils, plug wires, and stator coils, Hall Effect sensor?

    It is possible for an Upgrade Kit to be bad, but it is rare.

  3. #3
    Well, Damn..............

    Brand new battery, 12.77 volts at the terminals and CDI Red/Purp, but, 10.4v-10.3v at the CDI Red/Purp while cranking.

    Is the .1v-.2v difference of the stated 10.5v requirement enough to prevent proper CDI function?

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by SLT 700 View Post
    ...Is the .1v-.2v difference of the stated 10.5v requirement enough to prevent proper CDI function?
    Yep. It is the CDI itself that needs the voltage to be over a certain threshold.

    What is the battery voltage at the actual battery posts while cranking?
    A new battery should be over 11.0 volts while cranking.

    You want to see well over 10.5 volts at the CDI.

    If the battery post voltage is good while cranking, then remove and clean both ends of both battery cables.

  5. #5
    Ty K447 for the help.........

    With a new replacement battery, I'm getting 12.74v at the posts and 11.1v at the red/Purp CDI supply input while cranking..........

    I'm wearing out the starter and getting spark about 1/20........

    I'm going to try to exchange for a new CDI. 'Sure hope I don't hear that electrical parts are non-returnable......

    'Crossing fingers......................

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