I have a 97 Sportstman 500. I rode it about 5 minutes the other day. Shut it off and now no spark. CDI unit is only putting out about 10 volts to the coil. Most everyone states to change out the stator. I do have a used stator off a running 97 Scrambler 500-but it has 1 less yellow wire going to the regulator box in front of the radiator. Will this one work? or is that additional yellow wire necessary? thanks in advance

 

Welcome to the forum! Part numbers are different on the stators (probably for that wiring difference) Plus check that the connector ends are the same. Probably wouldn't charge back to the battery. Best just to pull your recoil cover and flywheel and just check your stator out. Could just be something simple as dirt/trash around the pickup coil. Plus early 500s were bad about flywheel magnets separating tearing up stators. OPT

 

thanks OPT. I removed the cover first and cleaned around the pickup and scothbrited around the stator. I also removed some rust from the pickup portion on the flywheel. All the magnets in the flywheel looked good-no damage. put it back together-still no fire.

Could I hook up the Scrambler stator to see if the stator is the problem? Would it just not charge the battery?

 

Sounds logical to me. Give it a try. First you might pull the black wire from the cdi (eliminates the kill circuit) Plus the black wire from the reverse limiter module and see if you have spark. OPT

 

thanks OPT. I did pull the black wire from the CDI-no spark, but I did not pull the one from the reverse limiter. I'll give that a try before swapping the stators. thanks for your help

 

Let us know if the stator works OPT

 

OPT, the stators will not interchange. The diameter on the Scrambler stator is larger and will not fit in the Sportsman flywheel. I did find 1 of the components on the stator was bad (no ohm reading) so I was able to swap it off of the Scrambler stator. That didn't fix the no spark issue. I removed the black wire from the reverse limiter-but still no spark. I finally replaced the cdi unit and that fixed it.

Thanks for all the advice/help!!!!

 

Have had more people on the forum have more cdi problems than I ever had. Most of my problems on the old ones were stators.Either burnt up or chewed up by pieces of magnets coming off the flywheel. Glad you found the problem. OPT

 

I have a similar issue, My Worker 500 -99 will not start ( produce a spark) unless i pull the killswitch wire on the board below the cover at the front of the Bike.
Once it starts i cant kill it with the off switch , it that a cdi problem or something else?