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Old 01-05-2012, 05:13 AM
GASportsman's Avatar
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HELP Please: 500 will not start

Hello again to all. I have an 03 500 sportsman ho and it will not start. After a new ignition coil, stator & pickup coil, and new cdi box, I still cannot get my machine to deliver a spark to the plug. I have checked the fuses/breakers in the pouches under the hood and they check fine. I am at a loss please help if you know what else i haven't checked. After reading many other posts I have unhooked the kill circuit and the speedo assembly but it didn't help. If I can't get her going shortly I will have some premium parts for an 03 because it only has 48 hrs on it total and about 5 mins on the new top end.
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Old 01-05-2012, 06:36 AM
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Since you know that you don't have spark I assume your starter is working which means that your kill switch circuit is not a problem. In times like this it is crucial that you have a good wiring diagram to trace down the problem. Have you checked the stator? Polaris uses the pull handle as a plug to keep out dirt. Sometimes water and mud can get in there during water crossings and cause grounding problems. Many times you can just clean the stator and re-install. Since I don't know your specific model that's about all I can offer, good luck and keep us posted so others can benefit from your diagnoses
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Old 01-05-2012, 08:46 AM
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2003 500HO spark left town

I have a wiring diagram in the service manual I bought, but the stator and pick up coil are both new from Ricky Stator. I contacted him and he told me to check the red and black/red wires while turning the engine over and my meter should read 20 to 30 volts. Gonna go home and try this. I have been using the starter but I think I am going to try the pull rope this time. I did clean a lot of junk out of the inside where the stator is but I have no ride time since replacing it so I know there is nothing in there...yet. I will keep posting until I find it. haven't had one whup me yet and this one ain't either. Good luck to the others who are having similar problems. i read all your posts so when you find the problem let us know, I might learn something.
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Old 01-06-2012, 03:23 AM
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Coil Gap

Ok folks I have found my problem. Little did I know the pickup coil and flywheel need to be very close together. after a call to a friend and speaking with an old shcool mechanic I went home took the pickup coil loose (had to notch the holes and grind the bracket to make it work) and set the gap with a dollar bill. The thickness of a dollar folded in half is perfect because I tightened the you know what out of it and it works fine now. Cranks every time you hit the switch. I folded the dollar in half so after it was tight I could slide it between the coil and flywheel unfolded. My coil was too far away from the flywheel and not picking up the signal when the magnet on the flywheel passed. Many of you may know this already but after a couple of months of not knowing it and finding it out I sure was a happy sole.
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Old 01-06-2012, 10:50 AM
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Awesome, I'm glad it worked out. Those are the kinds of problems that can make you pull your hair out if you don't know. But now you know and next time you service your stator/coil you will be able to properly setup the gap. This also goes for small engines (like briggs etc..)
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Old 04-02-2012, 04:41 PM
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im wondering if my bike has the same problem. i replaced the pickup and it ran awsome but a dog came out of my pull cord and smashed the casing and broke it. i fixed it and no spark. if i mess with the switch while i push the starter button it will fire and run great so i replaced the switch and same problem. i can turn switch on and off and get it to run but idk whats going on here. im about to pull my hair out lol
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