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  1. #1
    kensmith's Avatar
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    Burnt up stator ground wire- 1995 SLX 780

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    Well I just bought 1995 Polaris SLX780, it sat about 6 months started & idled great good response, the drive line & coupler are stripped so the ski won't move in the water, but that's not a problem to fix

    I also have a Kawasaki stand up & rebuilt the whole motor myself except splitting the crank & boring the cylinder. I used to race motocross & worked on my own bikes.

    Anyways I believe this CDI box is a bad design. I was using the shop vac to remove water and seen a little smoke I knew rite away the Battery cover was left off the pos. battery terminal, I grabbed it really quick & pulled it off the battery you can see some slight melted marks in some spots off the loom.

    I tested continuity with stator wire disconnected from CDI box & isolated from the other grds to battery terminal ground its still reading continuity @ almost 0 However the ski will not start (no spark) Has anyone had this problem & fixed it ? I'm thinking maybe the Stator but I hope not. Any info is appreciated. Thanx.
    Last edited by kensmith; 03-19-2013 at 08:05 PM.


  2. #2
    I transcend race Hombre! TBone14's Avatar
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    Quote Originally Posted by kensmith View Post
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    Well I just bought 1995 Polaris SLX780, it sat about 6 months started & idled great good response, the drive line & coupler are stripped so the ski won't nice that's not a problem to fix

    I also have a Kawasaki stand up & rebuilt the whole motor myself except splitting the crank & boring the cylinder. I used to race motocross & worked on my own bikes.

    Anyways I believe this CDI box is a bad design. I was using the shop vac to remove water and seen a little smoke I knew rite away the Battery cover was left off I grabbed it really quick & pulled it off the battery you can see some slight melted marks in some spots off the loom.

    I test continuity with stated wire disconnected from CDI box to battery ground its still good. How ski will not start (no spark) Has anyone had this problem & fixed it ? I'm thinking maybe the Stator but I hope not. Any info is appreciated. Thanx.
    Yep. Stator. You can test to verify, but I'd bet that's what it is...very common problem.
    Last edited by TBone14; 03-19-2013 at 01:21 PM.

  3. #3
    Click avatar for tech links/info, donation request K447's Avatar
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    Test each Black wire in the electrical box. The stator wire is not the only wire to suffer when a battery short happens.

    You say the Black wire to the stator is measuring zero ohms to engine case, when that Black wire is isolated from the other wires - correct?

    Have you ohm tested all the other stator wires? Especially check for shorts to ground on the other stator wires.

  4. #4
    kensmith's Avatar
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    Yes, the stator wire is close to O ohms @ - battery cable which comes off the block. I tested the stator & it ohm's out rite, but few wires that were supposed to be infinite open tested with resistance. I do work with 12 volts everyday, I think I tested them correctly, but going to recheck tonight.

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    Last edited by K447; 03-19-2013 at 12:17 PM.

  5. #5
    kensmith's Avatar
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    Thanks for the welcome

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    kensmith's Avatar
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    I guess I can just put pro 785 stator & coils if I could find some & that's the problem.

    I'm wondering if maybe the ground wire just melted into one of the coil wires or something.

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    Last edited by K447; 03-19-2013 at 12:17 PM.

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Pro 785 ignition is different from all other Fuji ignitions. The Pro 785 has a unique CDI (among Polaris stock engines) and fires the coils sequentially.

    All other blue Fuji engines (650, 750, 780) fire all three coils together, every time any cylinder needs a spark. This is called a wasted spark ignition system.

  8. #8
    kensmith's Avatar
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    Oh so they are not compatible ? Even with CDI & coils from 785.

    Yes I isolated the grd. Wire from the other I cut it from the other one it was tied together with in the grd ring. Then resoldered it to a new one.

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    Last edited by K447; 03-19-2013 at 06:10 PM.

  9. #9
    BlueFishCrisis's Avatar
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    I recently fried a stator wire by grounding the box. I discovered that while the ground wire was intact, it was barley still there. I would run a new ground wire from the stator to the ebox. To test if this solves the problem, you could jumper a wire from the battery to the ebox (any ground point). This will provide a good solid ground for testing. IF this works, replace the stator ground wire full length. This worked for me......

  10. #10
    kensmith's Avatar
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    I'll check it out.

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