I have a 2000 Sportsman 500 with issues. I have gotten the 4wd working properly now...only took $800. Soon as I get that fixed, another problem pops up.

It quit running one day. Kids were riding it, shut it off to eat and it's never started since. I pulled the plug, got a new plug and tested for spark and it has none.

I have swapped the CDI box with a unit off another running machine and still have no spark.

I removed the pull start cover, which was full of water. I cleaned all that up and cleaned all the magnets and such with scotchbrite and tried it again. No spark.

I have now pulled the flywheel off and completely removed the stator. I'm not terribly good with electrical but I have tested it to the best of my ability. I am fairly certain that this is my problem, I just want some confirmation.

Here are my results...

Red and Green should be 1.6 ohms...tests 1.6
BLK/Red and Green should be 446 ohms...tests 1.0m
White and White/Red should be 97 ohms...tests 101

Yellow and Yellow/Red should be .13 ohms...tests .3
Yellow to Ground should be infinity...tests infinity

Now as far as I can see the exciter coil BLK/Red and Green is definately showing bad. I am not sure about the charge coil Yellow and Yellow/Red.

Can anyone (OPT?) confirm these results for me? I bought this machine on mothers day, have replaced the hilliard clutch, strut housing, armeture plate, and 2 hub seals on the passenger side to get the 4wd working. I have replaced all the fluids. I have only had limited riding time on it and it's now been sitting for 2-3 months unable to start. I am tempted to light it on fire and probably would if it was insured. 2 other people have worked on it with no success.

I was on a PolarisATV forum, but there are alot of rude people and unhelpful answers on there. I have been lurking on here for quite awhile and the are some very helpful people on here for sure. I hope someone can help me with this and maybe I will be able to help someone else in the future.

 

I'll confirm it! Had a bunch like this that the pulse coil(white to white/red) was still in specs,but the exciter/charge coil was shorted out. Stators just don't like water. Try this place. Ricky Stator OPT

 

Awesome! I already knew you usually recommended them so I have their site bookmarked. I was just wanted to get confirmation before dropping $150. Thanks for your help, I will be ordering ASAP.

 

An update....

I got a new stator from Ricky Stator. Installed it and viola, the machine runs again. Pretty happy with that.

However...I am not terribly satisfied with the stator I got. It works and all, but the wiring harness is the problem. I installed it using the same route as the original wiring harness, but it is simply too short. Only by an inch or two but too short nonetheless.

Plus NONE of the connectors would connect. They appeared to be the same type of bullet connectors and rubber connectors but try as I might, I could not get them to connect. The bullet connectors would not connect. When I forced them as hard as I could, the female end expanded out to the point that the fit was loose and really poor. Whenever I tried to connect the rubber connectors the wires would get forced out, basically the same problem with the connectors not fitting together.

Even when I had the connectors joined the best I could, the machine still wouldn't fire as the CDI box wasn't getting a good connection.

In the end, being pressed for time and not wanting to have the machine down for longer than it has been, I cut the non working connectors off and made my own connections. I then used liquid electrical tape to seal up the new connections against the elements the best I could. Hopefully it works.

 

Never had that problem from Ricky's Stator before ,BUT did have one stator from them that had wires reversed in a three prong connector. Probably better the way you've done it and used liquid tape. Sounds like they may be getting a little sloppy in their quality assurance department if they have one! OPT