Polaris Outlaw 500, Service Manual

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7.7
ELECTRICAL
7
IGNITION SYSTEM
Ignition System Troubleshooting
No Spark, Weak or Intermittent Spark
• No 12 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 .005”
• Faulty CDI module
Circuit Breakers
The circuit breaker panel is located underneath the front cab.
Access can be gained by removing the cover. Removal of front
cab may be required for better access.
Cranking Output Tests
The following tests will measure the amount of output directly
from each component.
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 and with the spark
plug installed. The starter system must be in good condition and
the battery fully charged.
200 Watt 4 Stroke DC/CDI Ignition
Test
Connect
Meter Wires To:
Reading
(Without Peak
Reading Volt
meter)
Pulse (Trigger) White / Red and White 1.4 - 2.0 DCV
CDI Output White / Blue and Ground 200 - 400 DCV
15 Amp - System Main
10 Amp - Fan
5 Amp - CDI