07/07/2026
This 2001 ranger series 10 came in with a starting concern, where the engine would only crank over and start with jumper cables attached, even with a fresh battery on it. Inspection revealed that the charging system was not charging, causing a hard crank issue, as well as a lack of spark when cranking. Further diagnosis revealed that stator anperage was in spec at the stator plug, but not present at the voltage regulator. Upond close examination we found that the voltage regulator terminals had been changed, and that one of the pins on the stator wire had been crimped to the insulation by mistake rather than to the copper, leading to a loss of contact. We replaced the connection and confirmed that the charging system began charging as it should. We then moved on to diagnosing the loss of spark when cranking, and found that the pulse coil and exciter coil within the stator assembly were in spec, and that the coil and spark passed all resistance checks. We then found that no voltage was present at the coil from the cdi using a peak voltage tester, indicating that the cdi had failed. It was at this point that we realized an aftermarket cdi had been installed. The factory cdi has been long discontinued but we were able to source a used OEM polaris cdi, and confirmed that the engine started immediately without hesitation with the oem cdi installed. We then replaced the positive cable end using a proper hydraulic cable crimp and confirmed the side by side starts just as it did the day it left the show room. Finally we returned it to the customer ready to work!
As always, from our family to yours, thank you for your business and continued support!