so i had to re soder the red/black/red wire to the stator , but i do now have ohm readings , machine now has spark again (wahoo) , but still runs extremely rough my camshaft looks good and so do the valves , im lost yet again , its backfireing from the carb now , i took the carb off and inspected (very clean still since 3 months ago) i still blew it out etc everything looks good in there , is there any other suggestions? also fuel.air set to 1 1/2 turns out

 

should add almost sounds worse going 1 1/2 turns , like it idles very rough with backfires now

 

If you had to rework a new stator something doesn't sound right to begin with.. Check that pickup coil shows 97 ohms on the white and white/red wires. Distance on pick up coil to flywheel tab,.016 to .040. Try moving it in a little. Normal fuel screw setting should be around 2 to 2 1/2 turns. If you've eliminated the carb along with any cam lobe problems,valves set at .006,but back firing,still sounds like an electrical problem. Stator timing,Or stator itself even though you said it was new,possible cdi breaking down or even the coil.Just recheck resistance specs from the manual.Plus simple things like checking plug cap resistance,any small breaks in coil wire,plus pull the black wire from the cdi and see if it helps.

 

yeah noticed i re read my book wrong , set carb to 2 1/2 , pickup coil is at 97 , my gap is .026 , valves are good at .006 , cam doesnt look flat , i also have another cdi and coil out of the other 500ho , i havent tryed unplugging the black wire from cdi tho , plug cap is set and i get a really good blue spark . i will try pulling the black wire tonight

 

Old Polaris Tech - you are THE MAN! I dont know if people regularly thank you, but wow as I read through these threads I am amazed at how knowledgeable you are and it is a blessing to us all how willing you are to help.

For everyone - THANK YOU

 

My wheeler is acting like its running out of gear. It's over reving at 10mph. Back fires like a sob when I come off the throttle. I took the clutch cover off, pulled the clutch. Seems a little worn but not overly. Just put a new belt on and still having the same problem. It's almost acting like the primary clutch isn't squeezing the belt enough, so the belt isn't riding up on the primary. Need some advice please. Options on trouble shooting.or has anyone encountered any of the same issues??

 

Gave you a reply on your other post on this before I saw this one..It might help track down the problem.

 

Hey man sorry to bring this back alive but having the same problem with the rough backfiring and all, did you ever find a fix?? I'm stumped on this one

 

What year and model?

 

It's a 99 sportsman 335 4x4.