2005 Polaris Sportsman 400/500 Service Manual, Page 279Get 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
Test CDI Output
Connect Meter Wires To: WhiteBlue to Ground