I have a 02 sportsman 500ho, I put new cdi unit in and once it runs for a while and gets warmed up it starts spit and sputtering, I unplug black wire on the Cdi unit and runs fine. It make key switch not work to shut machine off but I just replug black wire in.
where does this black wire go and control.
Help please very frustrated

 

The cdi black kill wire ties into the ignition switch and left control circuit kill wires. You're bypassing these two switches by pulling the black wire from the cdi. Problem is either in the ignition switch or its wiring harness or the left control switch or wiring. Trace the wiring from both of these and see if you can find any bare wires.It's NOT unusual for an ignition switch or a left control switch to have problems internally. Ignition switch if faulty is cheap.IGNITION SWITCH KEY for POLARIS SPORTSMAN 500 HO 2002 2003 | eBay The left control switch is pricey.Polaris New OEM Handlebar Headlight Hi/Lo Beam Light/Kill/Stop Switch- Sportsman Also pull the two connectors from the left control switch,clean with contact cleaner and use some electrical grease. That could possibly be the problem area. If that doesn't help,then you need to check the wiring leading to both switches.