2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 239Get this manual
ELECTRICAL
IGNITION SYSTEM TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
GSpark plug gap incorrect GFouled spark plug GFaulty spark plug cap or poor connection to high tension lead GRelated wiring loose, disconnected, shorted, or corroded GEngine Stop switch or ignition switch faulty GETC switch misadjusted or faulty GWire harness or connections wet, corroded GPoor ignition coil ground (e.gcoil mount loose or corroded) GFaulty stator (measure resistance of all ignition related windings) GIncorrect wiring (inspect color coding in connectors etc) GFaulty ignition coil winding (measure resistance of primary and secondary) GWorn magneto (RH) end Crankshaft bearings GSheared flywheel key GFlywheel loose or damaged GTrigger coil air gap too wide (where applicable)should be .016-.040 (.4-1.0 mm) GExcessive crankshaft runout on magneto (RH) endshould not exceed .0024 GFaulty CDI module
CDI CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER
The following peak voltage tests will measure the amount of output directly from each componentA peak reading voltmeter must be used to perform the testsA variety of peak reading adaptors are commercially available for use with the Fluke 77 Digital Multitester (PV-43568) and other digital VOMs which will allow peak voltage tests to be performed accuratelyFollow the directions provided with the adaptorAll measurements are indicated in DC VoltsReadings obtained without peak reading adaptor will be significantly differentDisconnect the stator connectors from the CDI moduleTest output from exciter coil, pulse (trigger) coil, and compare to the chartThe following measurements are obtained when cranking the engine with the electric starter, spark plug installedThe starter system must be in good condition and the battery fully charged330 Watt Stroke (Sportsman 700) Coil Connect Meter Wires To: Reading (With Peak Reading Volt meter) 34 DCV 3.3 DCV