I have a prob and I am about to pull my hair out!!! My sportsman will cut off and lose spark intermittently. I have looked and looked for an obvious issue but none to be found. Sometimes it will crank right back up and sometimes it wont fire back up for an hour??? It is losing spark, that I know but I Where should I be looking for the cure? I dont want to take it out in the woods cause I cant trust that it will make it out. Sometimes it will run for long periods and sometimes just for five minutes before it just dies. I know I have fuel to the carb and well theres air. but I confirmed there was no spark with a screwdriver stuck in the plug cap and no spark against the frame. Any Ideas will be appreciated.

 

I would say check the battery and maybe the coil is bad. Im sure others will come along and give u their opinion

 

Intermittent spark loss can be a component beginning to short out;stator,cdi or even coils can break down when hot,BUT you really need manual to check resistance on stator,coil and also check for wiring short such as trigger coil area,have had wires come unsoldered from heat.Test light ,ohm meter really necessary tools if doing own repair work! Check that cap shows about 5000k ohms,plus could be plug wire has a bad spot on wire touching and shorting out,ignition switch shorting out,etc. One step at a time. Good luck

 

Around those years there was a problem with plug wires being pinched between the frame and front of the fuel tank also. You can ohm it out and it tests fine but won't flow the current needed to fire the plug. Caused very intermittent issues. Well worth checking out.

 

2004 Sportsman 400 was the culprit on the pinched wire problem! replaced A BUNCH!,but ANY THING CAN HAPPEN. Good luck

 

<div class="FTQUOTE"><begin quote>Originally posted by: old polaris tech

2004 Sportsman 400 was the culprit on the pinched wire problem! replaced A BUNCH!,but ANY THING CAN HAPPEN. Good luck</end quote></div>

I saw the problem on several 500's as well as 400's. Several different years as well. The bulletin stated for the 04 400's and 500's but it wasn't limited to that year only.

 

It has a new plug wire, mabey a week old. It is the wierdest thing???? does not seem to be temp related. I am going to order a new repair manual for it, which one do you guys recommend haynes, or Clyner, or??? Oppinions appreciated.

 

Polaris Shop manual better detailed and pics usually better quality,but price is higher.Clymer my second choice,pretty close in following factory manual,but pics and full info not as detailed. Either way a manual is the way to go!! Good luck