Ignition System Troubleshooting - Polaris SPORTSMAN 400 2003 Service Manual

ELECTRICAL
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
GSpark plug gap incorrect
GFouled spark plug
GFaulty spark plug cap or poor
connection to high tension lead
GRelated wiring loose, disconnected,
shorted, or corroded
GEngine Stop switch or ignition switch
faulty
GETC switch misadjusted or faulty
GWire harness or connections wet,
corroded
GPoor ignition coil ground (e.g. coil
mount loose or corroded)
GFaulty stator (measure resistance of
all ignition related windings)
GIncorrect wiring (inspect color coding
in connectors etc)
GFaulty ignition coil winding (measure
resistance of primary and
secondary)
GWorn magneto (RH) end Crankshaft
bearings
GSheared flywheel key
GFlywheel loose or damaged
GTrigger coil air gap too wide (where
applicable) - should be .016-.040²
(.4-1.0 mm)
GExcessive crankshaft runout on
magneto (RH) end - should not
exceed .0024²
GFaulty CDI module
CDI OUTPUT TEST USING
PEAK READING ADAPTOR
Re-connect all CDI wires to stator wires. Disconnect
CDI module wire from ignition coil primary terminal.
Connect one meter lead to engine ground and the
other to the ignition coil primary wire leading from the
CDI module. Crank engine and check output of CDI
wire to coil (130 DCV). Reconnect coil wire to CDI.
Output w/ Peak output tester
130 DCV
Average Output w/ Digital Voltmeter 20
DCV
10.14
CDI CRANKING OUTPUT
TEST WITH PEAK READING
VOLTMETER
The following peak voltage tests will measure the
amount of output directly from each component. A
peak reading voltmeter must be used to perform the
tests. A variety of peak reading adaptors are
commercially available for use with the Fluke t 77
Digital Multitester (PV- -43568) and other digital VOMs
which will allow peak voltage tests to be performed
accurately. Follow the directions provided with the
adaptor. All measurements are indicated in DC Volts.
Readings obtained without a peak reading adaptor will
be significantly different.
Disconnect the stator connectors from the CDI
module. Test output from exciter coil, pulse (trigger)
coil, and compare to the chart.
measurements are obtained when cranking the
engine with the electric starter, spark plug installed.
The starter system must be in good condition and the
battery fully charged.
250 Watt 4 Stroke
Coil Connect Meter
Wires To:
Exciter 1 Black/Red and
Red
Pulse White/Red and
(Trigger) White
CURRENT DRAW - KEY OFF
CAUTION: Do not connect or disconnect the battery
cable or ammeter with the engine running. Damage
will occur to electrical components.
Connect an ammeter in series with the negative
battery cable. Check for current draw with the key off.
If the draw is excessive, loads should be
disconnected from the system one by one until the
draw is eliminated. Check component wiring as well
as the component for partial shorts to ground to
eliminate the draw.
Refer to Illustration 1 on the next page.
The following
Reading
(With Peak Read-
ing Volt meter)
34 DCV
3.3 DCV