Ignition System Troubleshooting - Polaris SPORTSMAN 600 Service Manual

ELECTRICAL
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
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
Wire harness or connections wet,
G
corroded
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
Trigger coil air gap too wide (where
G
applicable) - should be .016-.040"
(.4-1.0 mm)
Excessive crankshaft runout on
G
magneto (RH) end - should not
exceed .0024"
Faulty CDI module
G
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 CDI to coil .
Output w/ Peak output tester
130 DCV
Average Output w/ Digital Voltmeter
20 DCV
10.20
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 Multimeter (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.
330 Watt 4 Stroke (Sportsman 600/700 Built
Before February 20, 2003)
Coil Connect
Meter
Wires To:
Capacitor Brown and
Charge coil Yellow
Pulse Black and
(Trigger) Red
330 Watt 4 Stroke (Sportsman 600/700 Built After
February 20, 2003)
Coil Connect Meter
Wires To:
Detection Orange and
White
Pulse Blue and Green
(Trigger)
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.
The following
Reading
(With Peak Read-
ing Volt meter)
34 DCV
3.3 DCV
Reading
(With Peak Read-
ing Volt meter)
3 DCV
190 Ohms