HI,

Last spring my problem started (no pun intended) with the starter. Replaced it with one from DB Electrical. Went great all summer. A few weeks ago heard a strange noise when I started the ATV. Then it would not re-start. Starter appeared to be running freely and not engaging. Battery was OK at full power so open up the flywheel side and to get at the bendix. Broken tooths on large gear meshing with starter gear. So I tried to wiggle it out...no way. Took the puller aout and remove the flywheel to get access at bendix. Replaced with bendix from DB Electrical. Work A1, engages properly but does not start anymore. Never had an issue with starting.

So do I start troubleshouting from the stator end or the spark plug end? Plugs appears to be a bitXX to get at. Is there an easy trick to remove the spark plug??

Thanks

 

Welcome! The starter bendix possibly could have damaged the stator,BUT I wouldn't spend the time trying to check it out! Common problem on the 2002 to early 2004 700(and also 600) carb models was for the Ducati ignition to fail. Some would last for years,some would show symptoms,hard to crank, popping back,etc,and some would just die and not crank back up,leaving people stranded. Replacement Kokusan ignition kits #2202602 consisted of a new flywheel,stator,cdi,coil,regulator/ rectifier,jumper wires and instructions. The kit is around $450. You can check Cycle Parts Ware House,Cheap Cycle Parts and other online sites for the best price. Dealers will be more expensive. I wouldn't even try to check this problem out as there are NO Ducati parts available,plus don't buy used Ducati parts on Ebay!!! Just read some of the problems on this forum in the expert and regular thread area along with doing a quick Google search on "700 Sportsman ignition problems". You're not the first or last one to have this problem.This should have been a recall,but wasn't as some machines would take a while to show symptoms. OPT

 

Thank you for your responce old polaris tech.

I was at the dealer today and they tried to sell me just the stator for 686.00 CDN. No mention on their parts software about a replacement. They only have been a dealer for 4-5 months.

I checked with Cycle parts warehouse and they refer to the replacement # the same that you provided me.

Is it a big job to install this kit? Would I need any special tools? I have some mecanical and electronic abilities but not in ATV. (clinical Engineering).



danthe99

 

The instructions are fairly simple to follow. You have to have either a steering wheel puller or a harmonic balancer puller to remove the old flywheel. This is really the hardest part. The rest is just step by step. Check around on the price. Some have said they've found the #2202602 kit for less than $400 US. OPT

 

Thanks OPT.

Best price until now is 446US. I will probably order today.

I really appreciate your help.

I'll check back with you in a few weeks (delivery to Canada might be 10-15 days)

Best Wishes of Health and Happiness to you and your family for 2013.

danthe99

 

The install directions are pretty good. I did mine a while back and the only issue I had was getting off the flywheel. My air tools did niot have enough oompf to take it off. Fortunately my neighbor down the road has better tools and it took him literally 2 m inutes to get it off. The rest of the install is just making sure you connect the new wiring correctly....You will need to trim a little plastic to get the new voltage regulator in. at least I think that was the part that was tight.....