OK, I have checked posts for 2 days now and using the search feature and cannot find what I'm looking for. My 2003 Sportsman 600 will run great for about 15 or so minutes until it gets hot enough for the fan to come on. Then the quad just dies. I have to wait about 30 or so minutes and then once it is cool enough, it will start up with no problem. I replace the Ducati CDI with another new one and it did the same thing. Took off radiator and soaked it in water/simple green for a day then cleaned between the fins till I could see daylight between all of them. Fan runs only when key is turned on. Charging great. All 3 circuit breaker, 2-20 amp and 1-10 amp, are good. I am at my whits end. I have been at this for 2 weeks and it is a royal pain. A little background about me. I have been working on motorcycles both street and dirt, cars and trucks for about 33 yrs. I was a helicopter mechanic in the Army for 23 yrs. Any help would be greatly appreciated.

 

Don't spend any more $ on Ducati parts! They're all junk.. The Kokusan kit replaces the Ducati system,isn't cheap,but if you try to keep the Duacti system it will just leave you stranded. Several places to get the #22202603 kit. Cycle Parts Warehouse,Cheap Cycle Parts, etc. It's not cheap,about $450-$500,but includes a new stator,flywheel,cdi,coil,regulator/rectifier,jumper wires and instructions. Here's the kit's pdf instructions you can download to see what's involved.http://www.google.com/url?sa=t&rct=j...,d.aWM&cad=rja

 

OPT, so you think its the ignition and not the temp.

 

What about the RM Stator kit that replaces everything to DC instead of AC. Includes all of the above also.

 

Don't know about this kit,but I do know about the Kokusan!Looking at RM's website,it doesn't show a kit for a 2003 model 600.Looks like it's offered on later model 600 engines,that already have the Kokusan ignition and appears that you can reuse the flywheel on these models.Doesn't show a flywheel with the kit! The Ducati flywheel I'm afraid won't work. I've done at least 7 or 8 kits or more and was still replacing them up until I retired over two years ago. This is a high quality Japanese kit that was even used in several of our KTM motorcycles we sold.

 

Thank you. So you still think its the ignition and not the heat that's causing this?

 

About 99% certain on this. Just do as search on all the 700 and 600 ignition problems on this and other forums,plus you can just do a Google search and you'll see what I mean..Affected all 2002 to early 2004 600 and 700 carb models..

 

Thank you again, just wanted to exhaust all my "cheaper" options before dishing out another $460+ after just dishing out $250 for the Ducati part.

 

Problem is I'm sad to say there are plenty of new Ducati combo cdi/coil units still for sale on Ebay and a few"working" used stators as the ads say. This "may" fix some machines for awhile,but when the stator goes out there is no Ducati replacement! The stator updates to the new Kokusan kit! Some unscrupulous dealers that know about this are unloading what Ducati parts they have.I found out the same way as you did early on. I ordered a cdi/coil for a customer as the stator ohmed out ok,but it came back later on non running. I checked the stator resistance and it crapped out. To my surprise when I looked up the stator part, it had the new kit (2202603) listed instead! This happened suddenly with NO warning to all of us Polaris dealers on the ignition change. Polaris IMO should have warrantied this problem,but didn't! Sorry that you had to learn the hard way on this..