Ignition System Troubleshooting; Cranking Output Tests - Polaris Trail Boss 330 2003 Service Manual

ELECTRICAL
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
No12 volt power or ground to CDI
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
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
Excessive crankshaft runout on
magneto (RH) end - should not
exceed .005²
Faulty CDI module
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
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.
77
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
CDI Output Yellow Blue
and Ground
Pulse (Trigger) Yellow/Red
Yellow
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
The starter
Reading
(Without Peak
To: Reading Volt
meter)
20 DCV
3.3 DCV
and
10.11