Ignition System Troubleshooting; No Spark, Weak Or Intermittent Spark - Polaris Magnum 2x4 Service Manual

ELECTRICAL
Ignition System Troubleshooting
Ignition System Troubleshooting
No Spark, Weak or Intermittent Spark
-Spark plug gap incorrect
-Fouled spark plug
-Faulty spark plug cap or poor connection to high tension lead
-Related wiring loose, disconnected, shorted, or corroded
-Engine Stop switch or ignition switch faulty
-ETC switch misadjusted or faulty
-Terminal board or connections wet, corroded
-Poor ignition coil ground (e.g. coil mount loose or corroded)
-Faulty stator (measure resistance of all ignition related windings)
-Incorrect wiring (inspect color coding in connectors etc)
-Faulty ignition coil winding (measure resistance of primary and secondary)
-Worn magneto (RH) end Crankshaft bearings
-Sheared flywheel key
-Flywheel loose or damaged
-Trigger coil air gap too wide (where applicable) - should be .016-.040" (.4-1.0 mm)
-Excessive crankshaft runout on magneto (RH) end - should not exceed .005"
-White stator wire (150W alternators) not grounded to engine
-Faulty COl module**
NOTE:
200 and 250 Watt Alternators -
If COl module is replaced, be sure to use the correct module for the
year and model you are working on. 1998-current COl modules are not compatible with pre-1998 Speed Limiter
Modules. If the COl module from a 1998 model is installed on a pre-199B model, intermittent ignition problems
may result unless the equivalent 1998 speed limiter module is installed with the COl module.
COl Module
Speed Limiter Module
Pre-1998 COl 1998-Current COl
Pre-1998 SLM Yes No (Yes if 1998 SLM is installed)
1998-Current SLM Yes Yes
Polaris Industries Inc.
10.19
12/97