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  1. #1

    Replacing stator and checking timing...

    My goal in this forum is start a precedure for replacing the stator and hopefully get some guidance along the way. I have a 2002 Virage 700 w/ single carb.

    After running through the precedure to test the hall effect sensor and stator, i found the Stator resistance between the black and purple wire was less then .3ohms (should be 5.5 ohms) and forced me to have to replace the stator. I had ordered a stator (part no. 4010172) from www.polarispartspitstop.com.


  2. #2

    removing the flywheel

    The first thing that i did was check the static timing. With a dial indicator, i set the mag cylinder to TDC and removed the peep hole. The flywheel has a guage that shows "0" in the center of the hole (see picture below). Since the timing was right on, i removed the bolt for the flywheel by placing rope in the mag cylinder.
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  3. #3

    Matching up the parts...

    When i purchased the ski approx 2 years ago, there was no spark to the plugs and i had to replace the CDI box. One thing i didn't realize is that in 2002 on some of the models Polaris installed a "high start timing" flywheels. From What I understand these flywheels were 10 degrees off from the standard ones and required a matching CDI box. The ski currently has a 4010569 flywheel and when i replaced the CDI box, i replaced it with part no. 4010404 and removed the 4163B which was hand written on the top of the old cdi box. This ski always had some hesitation off the start and I question if maybe the 4010404 isn't the right CDI box for the high start timing flywheels (maybe one of the more experienced guys could advise)?

    4010569 'High start timing' flywheel was stock on these models/years
    2004 VIRAGE
    2004 FREEDOM
    2003 VIRAGE
    2003 FREEDOM
    2002 GENESIS
    2002 VIRAGE
    2002 VIRAGE TX
    2002 FREEDOM
    2002 OCTANE

  4. #4

    Observing the flywheel cover...

    When removing the flywheel cover I noticed that there appeared to be metel shavings at the bottom of the cover. I'm still waiting for a flywheel puller but I'm curious if these shavings came off the flywheel or something off the stator? Either way it can't be good.
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  5. #5
    Moderator beerdart's Avatar
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    Interesting keep us posted.

  6. #6

    more to come once the stator comes in...

    ...

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by sirdave4 View Post
    When i purchased the ski approx 2 years ago, there was no spark to the plugs and i had to replace the CDI box. One thing i didn't realize is that in 2002 on some of the models Polaris installed a "high start timing" flywheels. From What I understand these flywheels were 10 degrees off from the standard ones and required a matching CDI box.

    The ski currently has a 4010569 flywheel and when i replaced the CDI box, i replaced it with part no. 4010404 and removed the 4163B which was hand written on the top of the old cdi box.

    This ski always had some hesitation off the start and I question if maybe the 4010404 isn't the right CDI box for the high start timing flywheels (maybe one of the more experienced guys could advise)?

    4010569 'High start timing' flywheel was stock on these models/years
    2004 VIRAGE
    2004 FREEDOM
    2003 VIRAGE
    2003 FREEDOM
    2002 GENESIS
    2002 VIRAGE
    2002 VIRAGE TX
    2002 FREEDOM
    2002 OCTANE
    The High Start flywheels have ten degrees MORE spark advance than the 'normal' flywheels.

    If you pair a high start flywheel with a 'normal' CDI, then you get ten degrees of ADDITIONAL spark advance across the entire RPM range. This would provide a very aggressive spark timing, but would risk engine damage from excessive timing.

    The 4010404 CDI came from a 2001 SLH, which according to the Polaris parts cross reference, came with the normal 4010189 flywheel. That means the 4010404 CDI is an incorrect match for the 4010569 flywheel.

    You need to match the flywheel and CDI timing advance. Either change the flywheel to a 4010189 flywheel, or change the CDI to one that is matched to the High Start flywheel.

    Note that these CDI are programmable. Randy at Watcon can change the timing on your 4010404 CDI to have the correct timing for your flywheel.

    BTW, where did the metal shavings come from?

  8. #8

    Got everything i need.

    To save money on the dial indicator (item#623-11.99) and flywheel puller (item#37824-14.99), i purchased both of them from Frieght harbor and the flywheel puller worked great.

    The source of the metal shavings was caused by the stator coming loose. It appeared one of the screws came loose on the stator and got lodged between the flywheel and stator which knocked the stator out of place (see pictures below).

    Question:
    Some of the experienced mechanics in the forum suggested to mark the stator before removing it. My question would be that there are three bolts that hold the stator into place, why would I mark the stator's exact placement when there is no why to adjust it (that i can see)?
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  9. #9

    another question

    I noticed that the edge of the flywheel is pretty beat up. Does that have any importance to the way it should function?

    The flywheel puller kit even includes the correct bolts (M8 1.25). I included a picuture of the flywheel puller.
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  10. #10

    Checking ignition timing

    Just finished replacing the stator on the Virage and the ski starts right up. I located a timing gun and was able to verify that the timing was advanced 10 degrees at 3k RPMs. According to the chart at 3000 RPMs the timing should be advanced 20 degrees but it's actually reading 30 degrees.

    Question:
    What is the chances of frying my engine when the timing is advanced 10 degrees and could that cause hesitation off the start?

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