10.24
ELECTRICAL
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Measure trigger coil gap with a feeler gauge. The gap
should be 0.4 - 1.2 mm (0.015 - .047 in.).
Ignition Troubleshooting
No Spark, Weak, or Intermittent Spark
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconn
ected, shorted, or
corroded
• Engine Stop switch or ignition switch faulty
• ETC switch mis-adjusted or faulty
• Wire harness or connections wet, corroded
• Poor ignition coil ground (e.g. coil mount loose or
co
rroded)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
pri
mary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Faulty ECU
Ignition Output Test Using Gap Tester
Re-connect all wires. Disconnect spark plug wire from the
spark plug. Connect gap tester lead to engine ground and
the other to the ignition coil primary wire leading from the
coil. Crank engine and check output. Spark should jump
a 1/4" (6mm) gap. Reconnect coil wire.
CHARGING SYSTEM
Current Draw - Key Off
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.
Crankshaft Position Sensor Gap:
0.4 - 1.2 mm (0.015 - .047 in.)
TEST
CONNECT GAP
T
ESTER TO:
R
EADING
Spark Gap
Output Test
Spark plug lead and
gr
ound
White/Blue spark
ju
mps 1/4" (6mm)
gap
Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will
occur to electrical components.
YB30L-B
Current Draw Inspection (key off)
Current Draw - Key Off:
Maximum of .01 DCA (10 mA)
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