Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 258 / 289

ELECTRICAL
10.30
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
G
Spark plug gap incorrect
G
Fouled spark plug
G
Faulty spark plug cap or poor
connection to high tension lead
G
Related wiring loose, disconnected,
shorted, or corroded
G
Engine Stop switch or ignition switch
faulty
G
ETC switch misadjusted or faulty
G
Wire harness or connections wet,
corroded
G
Poor ignition coil ground (e.g. coil
mount loose or corroded)
G
Faulty stator (measure resistance of
all ignition related windings)
G
Incorrect wiring (inspect color coding
in connectors etc)
G
Faulty ignition coil winding (measure
resistance of primary and
secondary)
G
Worn magneto (RH) end Crankshaft
bearings
G
Sheared flywheel key
G
Flywheel loose or damaged
G
Trigger coil air gap too wide (where
applicable) - should be .016-.040
″
(.4-1.0 mm)
G
Excessive crankshaft runout on
magneto (RH) end - should not
exceed .0024
″
G
Faulty 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
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. The following
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:
Reading
(With Peak Read-
ing Volt meter)
Exciter 1 White/Blue and
Ground
3 DCV
Detection White/Red and
White
185 Ohms
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.