DIY How to Troubleshoot & Repair a No Spark Condition on a Polaris Sportsman ATV Repair Manual
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- Опубліковано 22 лип 2024
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This video provides the steps that are outlined in the Polaris Sportsman repair manual. These should be followed when you have a no spark condition on your Polaris Sports, but this process will be the same or similar on many other ATVs also (Honda, Suzuki, Yamaha, Kawasaki). While there could be many other reasons why your ATV has no spark, this how-to process should provide a starting point on troubleshooting the problem.
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Disclaimer:
Due to factors beyond the control of Mark Jenkins, I cannot guarantee against improper use or unauthorized modifications of this information. Mark Jenkins assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Mark Jenkins recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Mark Jenkins, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Mark Jenkins. - Авто та транспорт
Affordable Multi-Testers on Amazon - amzn.to/2IYP7Mn
Polaris New OEM Circuit Breakers on Amazon - amzn.to/33F2nNV
Affordable Polaris ATV Manual on Amazon - amzn.to/32qoGH3
this vid just helped me find a poor ground at my ign coil mount...presto...we have spark again! thanks...2008 Trail Boss 330
I have the manual, and your vid really clarified the instruction for me, thanks dude!
Can u send me a copy of the manual
Thanks so much for this video Mark, it was a great help.
Thank you sir almost a year of trouble shooting this junk fourwheeler and you have dumbed it down enough for me 😊 I’m mechanical not electrical
Great video thank you for taking the time. I have spark and all the tests described in your video checked out properly in on my machine. The problem I am having is that it will only start manually with the pull cord or jumping with a 200A boost charger. It has a new factory Polaris starter, new pull starts assembly and a new battery as well. I have cleaned the flywheel and pickup eye off. Any suggestions will be greatly appreciated. Fuel system is good as well and carb is adjusted properly.
Thank you
Thanks Mark for your great videos,always well explanation.
thanks for the video man it helped me a lot!!!
Thanks buddy for the video really help i have sportsman 400 ,make me going crazy was not working like 5 years first I change the stare bendix carburetor fuel pump and i have not apart or something i have .
Going buy tester.thanks again
Dude! Awesome walk through... This will really help in diagnosis and not just throwing money at parts!!!
Incredible video man, much appreciated
Great video! I just replaced my trigger coil and stater. Still no spark trigger coil only showing 33 ohs could I have a bad new trigger coil?
Thanks for posting this
Dang dude many thanks!!! My Polaris trailblazer has a new stator but it's only putting out 63 ohms! So maybe the reason for weak spark.
Great video! I need a little help with my 03 Magnum 330 2wd. Any chance you could share a schematic that depicts physical circuit structure and wire colors. I have photo copys of a polaris shop manual with the diag flow chart just like the one you exhibit in this video, however I do not nor can I find the schematic w/wire colors and the pinpoint test result specs. My quad was running great for years, until one day my daughter was riding, as I watched her begin to ride off it back fired (through the exhaust) 2 or 3 consecutive times and then died. I got it to fire one time since. I don't have any spark.
Complicating matters beyond the no spark, my son figured he'd try to figure it out. His diag routine ultimately led to him disconnecting basically everything ( hard shell connectors, coil mount, the 2 CDI or ECM's, speedo head, all related steering column connections and all the grounds ) under the hood. If you can't share the manual, could you please denote the related wire colors and proper connection locations i.e. ign coil, wires to and from the ecm's and power/ground locations. I know there's only a few related connections, but I need to make sure of wire colors, power and ground loc's. My pulse coil has 60 ohms, not sure of the DC output from the pickup coil/stator.
The manual states that a PEAK VOLTAGE capture device is needed for diagnosis, is this true? Why would an old-school analog vom on a SUN VAT-40 starting and charging tester not be able to display the PEAK VOLTAGE and consistent needle swing while cranking? Also there are several spade connectors extruding out of the main harness that are NOT connected to anything..is that normal typically? I don't have a schematic to verify the correct wiring of any of them to determine whether or not they are used at all or for what purpose.
Thank you in advance for any help...I look forward to your reply!
Dave
all_city_petroleum@yahoo.com
Thank very much. Invaluable.
THANKS FOR THE VIDS. jUST FOUND MAN WHO HAS SEVERAL TOYS AND this will help. Sorry about the caps wasn't looking !!!!!!!!!!!
Where did you buy that ignition coil from? I have bought 2 on ebay, both ended up having about 2500ohms resistance without the cap so they didnt work. I can't seem to find one with 6300ohms as specified in the book.
Thank u for the video been looking everywhere for a video like this Cause I have that Problem with a Honda 4oo Ex and I replaced a whole Lot of part , and realized in the end that it is the stator So Now have to replace that, thank u again,
I enjoyed your videos, I have a few questions, where can I get the testing flow chart you used? I followed along and checked mine and the pulse coil, magneto , grounds are good, I still have no spark, I replaced the pulse coil, replace spark plug and the cdi box. How do you check the cdi box? My new box could be bad since everything else passed
hey ive been looking around the web and i cant seem to find that repair manual anywares. i have a polaris sportsman 500 efi ho 2006
I have a 2005 Polaris 500 h.o. 4x4 i have spark when i use the pull rope to start engine but when i use the electric start there is no spark what could be the problem here. I replaced with new battery. it will only start up if i use the pull start meaning pulling the rope to turn engine over. Thank you
I have a 2003 polaris Scrambler 500×4, it's been sitting for a few years, it doesn't have many hours on it but after sitting for so long the battery is dead, so I got another one and it won't idle properly. I know I need to get it tune up, we also have a 2×500, any idea on what or where to start?
I saw a video on how to test for a short on a truck or car using a test light. You simply disconnect the negative lead to the battery, hook up your test light to the lead, then put the probing end of the test light to the negative battery post. If the light comes on, you have a short. I was wondering if this trick is also valid for ATV's since they use a different charging system. Thanks
YES , I'm having issues with the first two wires on the ignition switch wiring to the quad, they got burnt and I cant find where they went?
This video is outstanding! My question is I have 104 ohms instead of 97 ohms at my trigger coil. Is there a tolerance? Problem is I have no spark and Im down to checking wiring and all associated components. Thanks
My polaris 500 sportsman showed codes for manifold air pressure sensor, air temp sensor and engine coolant sensor. Can you help me figure out what I need to check to fix these
Is this the same procedure to use on a 2002-03 polaris 6x6 500 with a carburetor ?? Replaced just about everything except ignition switch , and still no spark !!?? Any ideas ?? Thank you !!
I have a 2003 Sportsman 500 HO and I'm trying to change the spark plug. I took off the red cap and see threads but I can't figure out how to get to the plug. I tried to open the unit its sitting in but there seems to be a gasket and I don't want to destroy it. How do I get to it in order to unscrew it! Thanks. Beth
mark i have a prblm with my polaris 500cc 2000 its starts but when i accelerate it just dies and trows the gasoline out from the carburator, then it just shuts down, but i figure out i have weak spark, can you help me ill apreciate it thanks
Where did you get the pin leads?
how many ACV. will the coil need to make the spark plug to spark or have a spark???
I have a 99 magnum 500 ran beautiful one day I go to start it and no spark....I've used multi meter and I'm getting NO continuity between pin on coil to spark plug boot....took boot off nothing between coil and wire and also nothing between the boot itself....Also I had to check stator which was testing ohms by a black w red trace wire and the one next to it but I forgot the colors...The ohm meter is picking up nothing. So am I missing something or could all of these go wrong over night. I'm gonna need this kit along with a stator and new plug wire with boot. I just can't believe it was running one day then all this! Any help is appreciated
This is a great video but there's more reasons a Polaris will not get fire. Kill/Start switch if it's bad then pull the black wire on ur CDI box. If you get fire then change that switch. OR, its in the throttle housing for ur thumb control on handle bars. There's a kill switch incase there incase the throttle cable breaks or hangs up wide open. pop open the top and separate the contacts with a piece of wood. If you have fire then adjust them not to touch. good luck
whats the toggle switch on your atv for?
Hi mate, how are you doing? Grettings from Brazil. I hope you can help me out on this trobleshooting. Let me get strait to the point. I just got a POLARES 330 CC, 2003 and I realized that my CDI box is not working, something bad might happened. I did some researches on the internet, youtube and i notice the the best thing to do is basiclly replace it, get a brand new one. However, to get it down here is so expensive. So, I´d like to try a MOTOBIKE CDI BOX. What are you recommend? Have you ever try it? PLEASE HELP ME. I aprecciate it. Thanks so much. Excuse my inglish is bit rusty.
What would cause a polaris sportsman 700 2002 automatically shut off when I put it in reverse everything else is fine with the transmission I'm thinking there is a safety switch is bad or something I'm just got it and I'm leaning as I go
Good day, I really need your help. I have a Polaris sportsman 500, 2004 carburetor. I can’t find a spark, I checked everything as in your video, but everything is fine. Maybe you can send a wering diagram
Hi where did you get the stator?
So if the pulser white to ground is not open, would that indicate that the pulser has gone bad??
2001 trail boss. ok it runs fine on old cdi but wont shut off.
put new ignition and handle bar switches and stator still wont shut off even touching black on cdi to ground. so put new cdi on and now no spark even with black unplugged from cdi. any help ????
Where can I get that book
Great vid.. Where did you get the manual from?
my97 sportsman passes all these test it just won't start in real cold weather warm weather starts always when i place a heater front of motor for 10 to 15 minutes the machine starts right up, need help any tips would help
worked well my wire rubbed it had to splice fired right up
Just wondering how you test coil bolt
Trigger Coil how many acv. comes out of if ???
Will th ATV still run if pull started with a bad cap? My cap seems to be dead but it runs whne I pull start just no crank
Ok so my white to ground has 20 ohms and WHT to WHT red show 125 ohms so does this mean my pick up is bad because it is going to ground?
How can i rewire the ignition coil?
All i saw was the blue and white wire?
Hi Mark, I have a 2005 Polaris Magnum 330 4x4 I am also having a low spark. Great video by the way thanks Do you have a link where you got you pulse or trigger coil? I have been on Ebay but I cant find any. Any Ideas that will help Thanks Larry
+Mark Jenkins Thank you
How can I get the "ignition system testing flow chart" you show in your video?
www.manualslib.com/manual/817908/Polaris-Sportsman-400.html?page=342
I've watched this video and used it step by step for my no spark problem. I have a 2000 scrambler 500 HO 4x4. I've changed every electrical part. new stator and pulse coil. 3 different ignition coils. CDI box. voltage regulator. I didn't replace the reverse interrupt box. I seen a comment about the throttle box safety wires. I separated the contacts with a piece of wood and the damn thing had fire!!!!!! it even sputtered. I was soooo happy! been over a year saving money hear and there for parts. then I tried again would not start because once again. no fire. It had orange fire and now nothing. again. went back to this video and checked everything and everything looks correct readings. Any thoughts??
I also do have fire coming from black wire out of CDI box
I have a 2001 trailBlazer 250 with no spark.. can't find any trouble shooting..
Don’t get a reading on multimeter on stator does that mean it’s bad
Sooo, when the spark plug wire is being checked where does the other lead from the meter go to ??????
Well, it was great information BUT where's page two?
why do I have spark when I pull my start my 400 and with the starter I don't have spark
i have 2003 polaris sportsman 500 ho 4x4 atv. key on coil ground 5.2 omes nut to eng 19.6 omes lead to coil ground nut 36.7 jumpping around lead to wire with cap on nothing. white with red line to white 0 white to ground 0.red with black line to red 22.3omes red to ground 0.please help frank
nothing meening ol
Frank Taylor ninj
I know this is a old vid, but were he checked the pulse coil i dont have that same plug to check on my magnum
do you travel to call outs , all I can say is what did you say ?
That is srsly the first time i have ever seen an polaris broke.
Polaris 800 EFI 2005 no spark what to do ?????(((
Have the same quad,got lucky and tested for voltage,had test light clipped to ground,touched wire coming from CPS, it started,,wow,,how lucky,,
How do I get a copy of that Manuel?
Battery is dead. I never had a problem with it.
You can learn more about it on woodprix website I think.