I own a 2003 600 sportsman. The CDI model #4010785 died, and a new one cost $220.00 no guarantee that it will last. Polaris suggests a retro fit kit #2202603 for $474.06 plus 4hrs of labor.
Everyone who has models of sportsman 600 and 700 dating from 2003-2005 that the CDI has died should contact Polaris to see if they will do a recall.
I hate to spend more than $750.00 due to a manufacturing defect.

 

What about an aftermarket cdi? Wouldn't it be cheaper and give you better performance? Just a thought....

 

BTW, I like your quote: "Enjoy the ride, and leave no trash behind" I am so sick and tired of the trash people leave behind. Totally not cool! It's no wonder they keep shutting down riding areas...we have to police ourselves.

 

anything that gives more perfoormance puts alot of extra wear and tear on your machine. alof more heat and it is never good. i have an adjustable performance cdi on my race car it is a venom x10 crazy power pick the front end off the ground power but we do pistonds every 5 weekends and bloow up and 1 to 2 jet changes a night. we also run 2 temp gauges eghaust and water and rpm gauge i would stay with something stock.

 

No one makes an aftermarket unit. Every parts dealer and Polaris dealers do have any in stock. This CDI unit is hard to find anywhere.
Please owners of these bikes write to Polaris and complaint if you already replaced them.

 

i saw aftermarcket cdis for teh scrambler and that is the same engine i have a sportsman engine in my scrambler acualy.

 

The Scrambler CDI is not the same. For the Sporstman 600 it has 2 plugs on the bottom, one for 3 wires and the other for 2. It also has the sparkplug wires already built in one on each side.
Procom and other manufacturers do not make one. I have searched the web, bought magazines and called plenty of suppliers, no one has an aftermarket and Ducati the original manufacturer will no longer make them.

 

o wow so if it has teh spark plug wires built in then it has to be after teh coil of has a coil built in thats y noone else makes those all of the others are before teh coil i have seen.

 

Did you find a replacement? Which part did you use. Do you have any info about a recall?

I have a 2003 Sportsman 600 with 29 hours and 271 miles. It has been sitting in the garage for the last 2 years. I started it a few times during that period. Now it has no spark. Do you know of any way to test the CDI?

This will be my first and last Polaris. It looks like I bought a piece of CRAP that has a smooth ride, if you want to tow it behind something else.

I also had the drive belt delaminate at 56 miles. What a qualtity product.

Save yourself a lot of money and frustration - DON'T WASTE YOUR MONEY ON A POLARIS. I never will again.

Thanks for any info[img]i/expressions/face-icon-small-frown.gif[/img]

Some more info I found out

Polaris only used the CDI #4010785 until 2/23/03. After that the stator and CDI were changed to a different model. See http://www.worldofpowersports....UAL%20PN%209918610.pdf
The parts in question are on page D13.
Why would they do that? Probably because they knew that the part being used was defective. Why did Ducati stop making it? The same reason that Polaris switched - it was a defective design! Why doesn't Polaris do the stand up thing and recall the defective parts? They don't care about the consumers of their low quality products. They only care about taking their money.

7-1-08
I sent a couple of emails to Polaris and got back some stupid response thanking me for being a loyal friend. I sent a response that I am NOT their loyal friend, but thought that they should recall their defective product. As expected, nothing there.

I took it to the dealer and had the 2202603 retrofit kit installed. After 3-1/2 hours last Sunday it was still running fine. I was happy that the dealer, Valley Cycle in Bakersfield, matched the price from Cheapcycleparts.com on the parts, which was $100 less than list price. It cost me $680 P&L to get it repaired. I really don't have any complaint about the dealer, but I'll likely never buy another Polaris product due to the corporate attitude that you'll buy whatever crap they put out. They remind me of GM and Microsoft.

The 2007 Suzuki Vinson 500 I picked up last week has many more positives than negatives when compared to the Sportsman. If it is reliable over a period of time, Suzuki will have the upper hand when I purchase my next ATV.