ELECTRICAL
10.2
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
PV--43568 Fluket77 Digital
Multimeter
2870630 Timing Light
2870836 Battery
Hydrometer
2460761 Hall Sensor Probe
Harness
2871745 Static Timing Light
Harness
WIRING SCHEMATIC
SERVICE
NOTES
NOTE:
There are two different electrical
configurations for the 2003 Sportsman 400. Two
different wiring configurations were used. Refer
to the right hand corner of the foldout wiring
schematics in the back of the book to note the
differences.
ELECTRICAL SERVICE
NOTES
Keep the following notes in mind when diagnosing an
electrical problem.
GRefer to wiring diagram for stator and
electrical component resistance
specifications.
GWhen measuring resistance of a component
that has a resistance value under10
Ohms, remember to subtract meter lead
resistance from thereading. Connect the
leads together and record the resistance.
The resistance of thecomponent is equal
to tested valueminus theleadresistance.
GBecome familiar with the operation of your
meter. Be sure leads are in the proper
jack for the test beingperformed (i.e. 10A
jack for current readings). Refer to the
Owner’s manual included with your
meter for more information.
GVoltage, amperage, and resistancevalues
included in this manual are obtained
with a Fluket 77 Digital Multimeter
(PV--43568). This meter is used for
when diagnosing electrical problems.
Readings obtained with other meters
may differ.
GPay attention to the prefix on the multimeter
reading (K, M, etc.) and the position of
the decimal point.
GFor resistance readings, isolate the
component to be tested. Disconnect it
from the wiring harness or power supply.
TIMING CHECK PROCEDURE
1. The ignition timing check hole is in the starter
recoil/magneto housing. Remove the check plug.
NOTE: NOTE: The ignition timing marks are
stampedonthe outside of the flywheel. Ignition timing
must be inspected with the engine at room
temperature (68°F/20° C).
2. With the transmission in neutral, start the engine
and set engine speed to 5000 ± 200 RPM.
3. Direct the timing light at the ignition timing check
hole and check the ignition timing. NOTE: Donot
allowthe engine towarm up. Thetiming willretard
approximately 2° when the engine is warm.
If the ignition timing is not within the specified range,
adjust the stator plate position as described below.
Flywheel
Rotation
32
Timing
Pointer
30
28
EH50PL 30° BTDC @5000 RPM
Timing
Inspec-
tion
Hole
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