Ignition System Troubleshooting - Polaris PREDATOR 2003 Service Manual

IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
No12 volt power or ground to CDI
G
Spark plug gap incorrect
G
Fouled spark plug
G
Faulty spark plug cap or poor
G
connection to high tension lead
Related wiring loose, disconnected,
G
shorted, or corroded
Engine Stop switch or ignition
G
switch faulty
ETC switch misadjusted or faulty
G
Poor ignition coil ground (e.g. coil
G
mount loose or corroded)
Faulty stator (measure resistance
G
of all ignition related windings)
Incorrect wiring (inspect color
G
coding in connectors etc)
Faulty ignition coil winding
G
(measure resistance of primary and
secondary)
Worn magneto (RH) end
G
Crankshaft bearings
Sheared flywheel key
G
Flywheel loose or damaged
G
Excessive crankshaft runout on
G
magneto (RH) end - should not
exceed .005
Faulty CDI module
G
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 Fluket 77
Digital Multimeter (PV- -43568), which will allow peak
voltage tests to be performed accurately. Follow the
directions provided with
measurements are indicated in DC Volts. Readings
obtained without a peak reading adaptor will be
significantly different.
the adaptor. All
Test output from the CDI and pulse (trigger) coil and
compare to the table. The following measurements
are obtained when cranking the engine with the
electric starter, spark plug installed.
system must be in good condition and the battery fully
charged.
200 Watt 4 Stroke DC/CDI Ignition
Test Connect
Meter Wires
To:
Pulse (Trigger) White/Red
and White
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. Set meter to read DC Volts. Crank
engine and check output of CDI wire to coil.
Reconnect CDI wire to coil.
Output w/ Peak output tester
130 DCV
Average Output w/ Digital Voltmeter
20 DCV
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.
ELECTRICAL
The starter
Reading
(Without Peak
Reading Volt
meter)
3.3 DCV
7.5