I have a 2003 Polaris sportsman 600 twin which a previous owner had the ignition upgraded with the Kokusan Denik CDi and new flywheel, stator, regulator and ignition coil. The ATV is having ignition problems and I would like to purchase replacement for the CDI module (may be called ignition control module) and the ignition coil. Anyone know the part numbers for the ignition coil and ignition/CDI module?

 

Welcome to the forums.

You can look up the parts numbers here.

I would also check other sites on the internet for pricing.

 

Before you guessed at parts I'd go through the ignition checks that are in the 2004 Sportsman 600 service manual.That's what the update kit (2202603) is supposed to be considered. 2004 Polaris Sportsman 600 Service Manual PDF Download

 

I have down loaded the 04 manual. I see that it covers both types of Ignition parts. From that I assume if I order late year 04 parts they will fit my 03 with the conversion kit installed.
I will go through there check list for ignition before I order parts.
Thanks OPT

 

Yes the later model(after 2/23) parts are Kokusan. From the installation kit list I found #4010920 as the cdi used and it shows it's used on the 2004 and 2005 model 600s also if the cdi is what you've traced the problem down to.

 

It runs fine now. I replaced the pilot jet with a bigger one.
Symptoms were.
1 Starts fine and runs fine at a dead idle.
2 With the choke I could drive it with some backfiring.
3 would die or backfire when you tried to accelerate without the choke even after the engine was warmed up.
4 when it got up to about 35 MPH I could shut the choke off and it would accelerate up past 40 MPH quickly.
5 when the weather got cold it ran worse.
6 when the weather warmed up it ran better.
7 timing light flash looked steady even when bike was backfiring.

 

Timing light test is what a lot of techs still use and pretty accurate in checking if it's electrical related or not.Glad you found the problem.
That's the main advantage of efi machines in that they adjust fuel for temp and altitude despite being a pain in the rear when they do have
problems of their own.

 

I was surprised that the factory stock jet worked so poorly. The jet had the correct infor stamped on it to be a factory stock and as best I could it measured correctly.

 

That's why they have the general jetting chart in the owners and service manuals. Altitude and temperature works not only on the main jet,but can affect the pilot jet also. Don't know how many carbs we had to rejet for people that were leaving Texas for places like Colorado and altitudes from 11,000 feet and up. Down here at 600 feet above sea level the same machines with stock jetting would run a tad leaner just in cold temps but not enough to change jetting and have to do it again a couple months later.Keep the stock 45 jet in case you may need it later,but possibly the larger jet may even work better in warmer temps.