Please note : Before installing your new CDI upgrade kit, make sure to note where the wires were plugged. You can take a picture of you current set-up so you will be able to remember were to connect the wire of the new CDI.


Table of contents

INTRO : Can I install the upgrade kit ?
FIRST STEP : Verify that your stator is working
SECOND STEP : Remove the old CDI
THIRD STEP : Find were to connect the CDI to the switch
FOURTH STEP : Installing the new CDI


INTRO : Can I install the upgrade kit ?


The RM40000 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

  1. Open your wire panel in the front of your vehicle
  2. Locate your stator plug. You will need to test your stator through that plug.
    Watch related video

  3. Check if your pick-up coil is functioning
    Watch related video

  4. Insert the first multimeter probe in the WHITE wire
  5. Insert the second multimeter probe in the WHITE/RED wire
  6. Check your reading as follow : 
    1. Reading of 115 ohms +/- 20% : Pick-up coil good, you can install the upgrade kit
    2. 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
  7. Check the first source coil by inserting the first multimeter probe in the RED wire
  8. Insert the second multimeter probe in the BLACK/RED wire
  9. Check your reading as follow : 
    1. Reading of 445 ohms +/- 20% : Source coil good. You can install the upgrade kit
    2. Reading of O.L.  : Source coil broken. You still can install the upgrade kit
  10. The Polaris Ignition Upgrade Kit is by-passing the source coil. You can install the kit even if the source coil is broken.
  11. Check the second source coil by inserting the first multimeter probe in the RED wire
  12. Insert the second multimeter probe in the GREEN wire
  13. Check your reading as follow : 
    1. Reading of 4 ohms +/- 20% : Source coil good. You can install the upgrade kit
    2. Reading of O.L.  : Source coil broken. You still can install the upgrade kit
  14. 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

  1. Unscrew your old CDI box
  2. 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.
Watch related video

  1. Turn your key switch to "Accessories" or "On"
  2. In your wire panel, use a current checker tool to find a connector that has current in it
  3. Turn your key switch to "Off"
  4. The current checker tool should goes off indicating that the key switch control current.
  5. 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.
  6. Plug the new CDI red wire in this connecting slot.


FOURTH STEP : Install the new CDI

  1. At this step, you should already have plugged the red wire in the accessories slot in the wire panel.
  2. Connect the new CDI connectors to the same vehicle connectors of your vehicle
  3. Try to start your vehicle : 
    1. If it starts, go to step 4
    2. If it doesn't start, check your connections, then retest your stator
    3. If it still doesn't start, call our customer service line for assistance
  4. 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. ***