Ihave a 95 polaris magnum 425 4x4 the stator has 6 magnets inside have a flywheel from 96 that the magnet is one continouse circle inside will this work and was it a desighn change

Question moved from Cars and Trucks to model category.

I have two thoughts on this.

You either have water in the electrics from hosing the mud off, especially if you used a power washer.

Or

If mud and water got into the stator and coated the sensor for the CDI. It is magnetic, but in close proximity.

Basically strip and clean and spray WD40 in connectors.

Other ideas here. The ATV forums are a great resource.

https://www.google.com/search?q=2004+polaris+sportsman+600+backfiring

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Check the stator which is in on the lower/left side of the engine opposite the belt, also triple check all wiring, it’s got to be something simple.

check conections on new parts just had that deal new cdi had one wire that pushed out just enough to lose contact. sounds strange but it happens.

check the hub fluid?

Check the Flywheel key. It should be locked under the pull cord, where the stator is located. I will be a small piece of metal that slides into the spline from the engine and the stator. If it is worn the stator will rotate off the spline and the timing will be off, she won't start and if she does will be really rough and backfire, sputter and have power loss.

check to see if voltage is coming off the stator while running, AC volatage, from all 3 wires. if thats good you prob need a regulator/rectifier.

115 ac volts at idle seems very high to me. if all 3 coils are putting out the same voltage I'd say its ok.

Check to see that the pinion gear of the starter is hooting out and engaging the flywheel.
And if it is working it is possible that you have missing tooth/teeth on your flywheel and the starter cannot turn over the engine because of that.

Polaris 325 MAGNUM 4X4 HDS A00CD32FA Parts Manual

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Some of the Polaris have magnetic locking hubs there is a little black box up in front if I remember right it has three wires coming out of it I think two yellow and one red this unit controls the front hubs
I bypassed this control one time by running a low voltage 12 volt supply to the front hubs used a toggle switch to activate the 4wd when needed it was a old farm bike and the guy did not want to spend the money to replace the control box