So I got this ATV a couple weeks back and rebuilt the recoil as it had self destructed on the previous owner. After the rebuild I took the bike out only getting a few hundred yards before it died with no spark. Pulled the recoil only to discover the pulse coil had been shattered by something. I cleaned out any foriegn objects from behind the flywheel and waited for a new coil to arrive.
New coil gets here and I put it together and take I out once again only to get a few hundred yards and no spark again. Same damage to pulse coil??? Does anyone know whats going on here?
I am sure glad I didn't spend 96 bucks at the dealer for the coil!
One other thing cropped up last night also. The starter would spin and not engage the flywheel sometimes.

 

Pull the flywheel and look closely at the magnets. Probably flaking off damaging the pulse coil. Have had em destroy whole stators. There is a newer updated flywheel that has the magnets inclosed and not open. Look here on your model under "magneto".Browse As far as the starter not spinning,pull the starter bendix(gear shaft) out and see if you can clean it up and grease it to where it kicks out and back properly,if it needs replacement here is one of the cheapest places.DB Electrical - Polaris OPT

 

Thanks for your reply OPT. I just looked for a flywheel and the cheapest I can find is 350 shipped ouch! Do you know what thread/size the bolts are for pulling the flywheel? I have the puller only none of the bolts fit.
Also I will check out the starter bendix and see if I can revive it.

 

Should be 8mm bolts 1.25 pitch if I remember correctly. OPT

 

So I took off the flywheel and found it to be the updated one magnets built in. I did however find a piece of the recoil attached to the magnets! I did not find anything else in there! I am going to test the stator to make sure it is functioning as it should.

 

At least you saved some money on a flywheel! Your model evidently was built after the updated flywheels were used! Looks like the ratchet lever off the recoil. Check the plastic reel carefully as they usually crack when this happens. If reel,main spring,etc is ok then sounds like you need a new ratchet and small ratchet spring. Look at the recoil parts. Browse OPT

 

I have already replace the ratchet, recoil rope, 2 springs and pull rope. Recoil is fully functional 180 bucks later!

 

Could have been much worse! Good luck. OPT

 

Thank OPT!
Just one last question! What tests can I do on the stator without running the bike?

 

Resistance test on the stator to cdi Red(or Green?) and red/back wires should ohm out about 446 ohms + or - 20%. I'll check to see if I have the schematic and see if this is correct.. PLUS the new "sticky" has manuals you can check out also. OPT