polaris sportsman 500 no spark

tbutler01 · #1 (**permalink**) 01-25-2012, 10:01 AM

Hi, guys. Need a little help. Working on my friends 2001 Sportsman 500 HO. It has no spark. Here's what I have done: disconnected the black wire from the CDI unit - still no spark. So i started to test the wiring. Put my volt meter on the white and white/red wires from the trigger coil. While cranking the engine, I did not see any voltage on the wires (AC or DC). I then ohmed out the two wires and got about 95 ohms between the wires. I couldnt find a three wire connector going into the CDI but I did find a two wire connector which was red and I think black. Ohmed these out and got 9.5 ohms. Nothing was shorted to ground. Checked all the connections and they looked good. My question is should there be any voltage on the W/R to W wires while cranking? Is there any other tests I can do without pulling the side cover and flywheel off? Also....the pull rope is broke off but was running after that for awhile. Please help! I get a mini-chopper if I get his Sportsman running! Ha, Ha! Thanks a bunch!

**Bruce!** · #2 (**permalink**) 01-25-2012, 04:52 PM

Welcome to the board!

tbutler01 · #3 (**permalink**) 01-25-2012, 06:19 PM

Thanks, Bruce. Know any stator experts?

GASportsman · #4 (**permalink**) 01-26-2012, 03:08 AM

Ricky Stator in CA is good, I bought one from him and he gave me all kinds of info as to what to look for and the correct way to install it.

tbutler01 · #5 (**permalink**) 01-26-2012, 07:21 AM

Thanks for your help. I am having trouble downloading the service manual that is here on the site.

All I get is the downloader program. Can one of you guys send me a copy of the manual for this 2001 Sportsman 500 HO? I'll buy you a beer! LOL!
Thanks!

tbutler01 · #6 (**permalink**) 01-26-2012, 06:16 PM

The wiring from the stator seems to check out per the specs. I noticed tonight that when I turn the ignition on and try to start the engine.......I get one spark at the plug then nothing!!???

Any ideas?
Thanks!

kcaves · #7 (**permalink**) 01-27-2012, 03:12 AM

if I recall right, I had one that did this and I want to say it was the ignition switch

tbutler01 · #8 (**permalink**) 01-28-2012, 05:20 PM

Ok guys.....I fixed it! Pulled off the side cover to check out the stator and found that a piece of the broken pull rope had smashed into the pickup coil and bent it back away from the flywheel. I was able to straighten it back up, wallowed out the mounting holes for adjustments and remounted with a dollar bill for the gap adjustment! Worked like a champ! Runs super now with no missing or backfires! Hope this helps someone else!
Thanks!