Polaris 2005 SPORTSMAN 400, Servise Manual

Page: 280 / 312

ELECTRICAL
10.20
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
OR A VOLT METER
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. Reconnect coil wire to CDI.
Test Connect Me-
ter Wires To:
Reading
CDI Output White/Blue to
Ground
300 Volts DC
CDI CRANKING OUTPUT
TEST
The following peak voltage tests will measure the
amount of output directly from each component. A
peak reading voltmeter can 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 the detection and pulse
(trigger) coil, and compare to the chart. The following
measurements were 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 DC/CDI Ignition
Test Connect
Meter
Wires To:
Reading
(With
VOM)
Reading
(With Peak
Reading
Adapter)
Pulse Coil White/Red
and White
0.15 Volts
AC
4.5 Volts
DC
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.