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  1. #1

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    94 sl650 burnt black wire from box to stator

    my ski was running great and all of a sudden shut down, burning black wire from box to stator. now starter won't engage. i replaced wire and stator but still no starter. plus it arcs blue when you hook up battery cable. in process of replacing complete black box, should replacing box fix problem ?


  2. #2
    Appologizes for the last user title katz1002's Avatar
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    check all your grounds first then start dumping cash into it

  3. #3
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    The reason the wire melted was because of a faulty ground.

    Check the battery ground connection at the engine plate. Also check the grounds inside tha elec box.

    Did you replace the stator, or just the ground wire on it?

    Starter cable shouldn't arc when connectiong. Something is shorted still.

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by xlint89 View Post
    The reason the wire melted was because of a faulty ground...
    I am going to disagree on this one.

    I suspect the plastic cover for the battery is missing, and the positive post of the battery touched the electrical box shell. That creates a short circuit, and the heavy current from that short runs through the black wire to the stator.

    That burns out the stator black wire, and often the rest of the stator wires. It can also burn some of the black wires and terminals inside the electrical box.

    A blue spark when connecting the battery means there is still something shorted in the electrical system. There should be very little or no spark when connecting the battery.

    Disconnect the battery, and start checking wires and connections with an ohm-meter.

    Also make sure you dd not reconnect the battery polarity backwards.

  5. #5

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    i replaced black box, breaking open both boxes and hooking every wire to correct post. starter now spins engine over great and blue spark is gone when battery cable is hooked up. now it has no spark to plugs. what do i need to check to get fire to spark plugs ? box came from running ski.
    during replacement of stator i plugged off oil pump so i can pre-mix gas, don't know if that would have anything to do with it but thought i better add info.

  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by m00n1957 View Post
    i replaced black box, breaking open both boxes and hooking every wire to correct post. starter now spins engine over great and blue spark is gone when battery cable is hooked up. now it has no spark to plugs. what do i need to check to get fire to spark plugs ? box came from running ski...
    What year and model Polaris did the replacement electrical box come from?

    What components from the new box did you use, and what parts from the old box?

    Work through the no-spark diagnostics section in the service manual.

    Check the stator ohms, and check for shorts to ground from each stator coil, per the manual.

  7. #7

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    i used everything from new and nothing from old, box came from a 94 sl750. i cracked open both boxes and spliced every wire making sure it went to the same post inside new box. there were more wires coming from new box, i just used the ones that i needed that were on ski, the new one probably came from a ski that had trim and digital display and mine didn't.

  8. #8
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Make sure your lanyard is installed.

    Have you ohm tested the stator?

    Did you replace the stator?

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