06-18-2008, 08:59 PM #1
- Join Date
- Jun 2008
crazy, but thinking about disabling my lanyard
New to the forum. And definitely not a mechanic. But I need input. I have a 1999 Polaris Genesis. Fantastic craft! But this is the second time in one year that "some connection between the lanyard and the starter" has crapped out. In other words, when the lanyard is not in place it turns but does not start - as it should. When the lanyard is in place, there is nothing, silence.
06-18-2008, 09:26 PM #2
Its not a problem with the lanyard at all. In the electrical box, there is a red/purple wire coming from the cdi...remove it from the red connection, and move it to a spare orange connector on the board. Should resolve your issues. It's a known problem. The CDI stays powered up, and thinks the engine is running, so it wont allow the starter to run. This adjustment makes sure the CDI gets powered down when the engine is off.
06-18-2008, 09:26 PM #3
You are bound to get help here, to fix this.
But I would not recommend bypassing this safety feature...!
Ooops...looks like PolarisNut has got you covered!
Welcome to the Hulk...!
06-18-2008, 09:28 PM #4
Good job Nut...I remember the bulletin but not the details. Thanks
06-18-2008, 10:01 PM #5
- Join Date
- Jun 2008
Will give it a try over the weekend. This forum is great! Can't wait to read on.
06-21-2008, 06:10 PM #6
- Join Date
- Jun 2008
Not sure about the "available orange slot on the board". Is it actually part of the electrical box? Please elaborate...
Told you, I may be an ER physician, but no mechanic.
06-21-2008, 06:22 PM #7
- Join Date
- Jul 2007
- Cedar Rapids,Iowa
It will be a open spade where another orange wire is plugged into the board. and should have the letters OR ...or something like that.
06-21-2008, 06:23 PM #8
Welcome to the forum!
Please use the advice above to retain the safety feature of your PWC.
06-21-2008, 07:52 PM #9
06-21-2008, 10:16 PM #10
Below is a step by step but Instead of using the jumper wire, simply put the red/purple wire to the orange spade on the electrical box.
Here is the cdi jumper wire TSB for most domestic models that are hard or will not start when hot.
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 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.
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
Connect RED/PURPLE jumper wire to RED/PURPLE male connector 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
This isn't your box but you can see where the red/purple is and where you want to attach that red/purple wire from the CDI to the orange spade on the terminal board.
Last edited by ph2ocraft; 06-21-2008 at 10:48 PM.
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