CDI Unit Polaris Sportsman 335 400 500 Magnum 425 500 Ranger 425 500 OEM 3084691 3085382 3085564 3085639 3086235 3086982

CDI Unit

2002 Polaris Sportsman 500 6x6 Carb
2002 Polaris Xpedition 425
2001 Polaris Big Boss 500 6x6
2001 Polaris Sportsman 500 4x4 Carb
2001 Polaris Sportsman 500 6x6 Carb
2001 Polaris Xpedition 425
2000 Polaris Big Boss 500 6x6
2000 Polaris Magnum 500 4x4
2000 Polaris Magnum 500 HDS 4x4
2000 Polaris Scrambler 400 2x4
2000 Polaris Scrambler 500 4x4
2000 Polaris Sportsman 335 Carb
2000 Polaris Sportsman 500 4x4 Carb
2000 Polaris Sportsman 500 6x6 Carb
2000 Polaris Sportsman 500 RSE Carb
2000 Polaris Worker 500
2000 Polaris Xpedition 425
1999 Polaris Big Boss 500 6x6
1999 Polaris Magnum 425 4x4
1999 Polaris Magnum 500 4x4
1999 Polaris Scrambler 500 4x4
1999 Polaris Sportsman 335 Carb
1999 Polaris Sportsman 500 4x4 Carb
1999 Polaris Sportsman 500 RSE Carb
1999 Polaris Worker 335
1998 Polaris Big Boss 500 6x6
1998 Polaris Magnum 425 2x4
1998 Polaris Magnum 425 4x4
1998 Polaris Scrambler 500 4x4
1998 Polaris Sportsman 500 4x4 Carb
1997 Polaris Magnum 425 2x4
1997 Polaris Magnum 425 4x4
1997 Polaris Magnum 425 6x6
1997 Polaris Scrambler 500 4x4
1997 Polaris Sportsman 500 4x4 Carb
1997 Polaris Xplorer 500
1996 Polaris Magnum 425 2x4
1996 Polaris Magnum 425 4x4
1996 Polaris Magnum 425 6x6
1996 Polaris Sportsman 500 4x4 Carb
1995 Polaris Magnum 425 2x4
1995 Polaris Magnum 425 4x4
2004 Polaris Ranger 500 Series 11
2003 Polaris Ranger 425 2x4 Carb
2003 Polaris Ranger 500 Series 10 4x4
1999 Polaris Ranger 500 6x6

OEM
3084691
3085382
3085564
3086235
3085639*
3086982* 

INTRO : Can I install the upgrade kit ?


The CARM40000 upgrade kit can upgrade your ride from AC power to DC power even if your stator is broken. Please refer to the following guide to know if you can install the upgrade kit:


You can install the upgrade kit :

When both your source coil and pick-up coil are working in your stator

When your source coil in your stator is broken, but your pick-up coil is working


You can't install the upgrade kit :

When your pick-up coil is not working

** It is possible to upgrade your ride even if your pick-up coil is not working. You will need to open your stator case, change the stator or the pick-up coil and then you will be able to install the upgrade kit. **

FIRST STEP : Verify that your stator is working

    Open your wire panel in the front of your vehicle
    Locate your stator plug. You will need to test your stator through that plug.
    Insert the first multimeter probe in the WHITE wire
    Insert the second multimeter probe in the WHITE/RED wire
    Check your reading as follow :
        Reading of 115 ohms +/- 20% : Pick-up coil good, you can install the upgrade kit
        Reading of O.L. : Pick-up coil broken, you will need to change the pick-up coil or the stator before installing the upgrade kit
    Check the first source coil by inserting the first multimeter probe in the RED wire
    Insert the second multimeter probe in the BLACK/RED wire
    Check your reading as follow :
        Reading of 445 ohms +/- 20% : Source coil good. You can install the upgrade kit
        Reading of O.L.  : Source coil broken. You still can install the upgrade kit
    The Polaris Ignition Upgrade Kit is by-passing the source coil. You can install the kit even if the source coil is broken.
    Check the second source coil by inserting the first multimeter probe in the RED wire
    Insert the second multimeter probe in the GREEN wire
    Check your reading as follow :
        Reading of 4 ohms +/- 20% : Source coil good. You can install the upgrade kit
        Reading of O.L.  : Source coil broken. You still can install the upgrade kit
    The Polaris Ignition Upgrade Kit is by-passing the source coils. You can install the kit even if the source coil is broken.


SECOND STEP : Remove the old CDI box

    Unscrew your old CDI box
    Disconnect the wire from your vehicle
    *** Beware : Please note which connector goes where. You will need to plug the new CDI in the connectors

THIRD STEP : Find where to connect you new CDI the the key switch

Since your new CDI provide DC power, you want to be sure that the current is cut when you shut off your vehicle. For this to happen, you need to connect the DC input wire to a connector that provide DC current when the key switch is on, but stop providing DC current when the key switch is off.
    Turn your key switch to "Accessories" or "On"
    In your wire panel, use a current checker tool to find a connector that has current in it
    Turn your key switch to "Off"
    The current checker tool should goes off indicating that the key switch control current.
    If not, repeat steps 1 to 4 with another connecting slot until you find the right slot. Usually, the accessory wire is identified with a Red/White wire on your vehicle.
    Plug the new CDI red wire in this connecting slot.


FOURTH STEP : Install the new CDI

    At this step, you should already have plugged the red wire in the accessories slot in the wire panel.
    Connect the new CDI connectors to the same vehicle connectors of your vehicle
    Try to start your vehicle :
        If it starts, go to step 4
        If it doesn't start, check your connections, then retest your stator
        If it still doesn't start, call our customer service line for assistance
    Screw your new CDI in the same holes of the old CDI.
    *** Beware : The new CDI might not fit exactly in both vehicle holes. In that case, you should install the CDI in an angle and screw the CDI in only one hole. ***