I have replaced the whole recoil and replace what you show 4 times and it still keeps on breaking

 

If you're going through that much trouble replace the whole blamed thing with an after market one and see how it does.New Polaris Complete Recoil Starter Pull Start Assembly Sportsman 500 1996 2011 | eBay Recoils shouldn't be breaking like this. May not hurt to recheck the spring on the compression release assembly.

 

Hi opt. I got the new stator and pick up coil wired in. Waiting to install them until I gethink everything cleaned up to where they go. In the mean time I read my book about testing the ignition coil and I figured what you were talking about my results are
Primary (which is the tab) to where the coil gets mounted with the bolt is 1.1 ohms
Primary to secondary is 6.12k ohms
Plug cap is 5.5k ohms.- you said it should be 5k ohms but my book says 3.4k ohms. Also in a previous comment you said, "Coil Secondary(coil to wire(plug attached) 6300" to test this I had to screw the plug cap or spark plug boot off the wire so I don't understand this.
Thanks for the info and what you do! Hope you are enjoying that good weather down there we got 4 inches of rain and now it is 33 degrees outside!!!

 

Look close on the plug cap resistance specs.. Shows 3.4 to 6.3 on plug caps on the atvs up to the 400 2 stroke. The 500 in the same column shows a 5k ohm cap. I've got two different manuals on this and both vary a little on the secondary,but both still show the cap alone as 5k. ALL you're doing is testing the secondary(coil tab to wire with plug cap installed) should be around 6300 ohms. If you remove the resistor plug cap,it alone should show around 5k or a tad less measured at both ends.

 

Cleaned everything up and tested again.
Tab to ground- .3
Tab to wire(where it goes to coil)- 6.25k
Tab to spark plug boot- 11.72k
Spark plug boot-5.45k
I am so confused

 

Tab to spark plug boot- 11.72k

If this is the reading from the tab to the plug cap(installed on the coil wire) then this reading is too high. Check the plug wire itself for any abrasions,cuts,etc. Some models the plug wire could be remove from the coil,not sure on the 98.
Plus what do you show on the coil tab to the bare end of the wire,cap removed?

 

Tab to wire with spark plug boot removed is 5.89k the wire does come off the coil, it threads off just like the wire to the spark plug boot. Tab to where the wire goes to the coil is 5.92k but 30 min ago I got 6.25k there. The wire is in great shape

 

Just for the heck of it go to any auto supply,get a length of 7mm coil wire and hook the cap back up. The coil primary shows good(.3) plug cap is slightly over(5.45k but this can be because of the meter) You can secure the new coil wire into the coil with a little silicone.Hook everything back up and see how it runs. If that doesn't help,then on your earlier post on the pick up coil(124 ohms versus 97) a little over the 10% resistance allowed, that could be the problem. These are cheap to replace.http://www.ebay.com/itm/Stator-Pick-...hT~Nam&vxp=mtr
Forgot,brain dead again... Since the plug wire comes out on this coil just check end to end resistance on it. Should 0 out. If it does the wire is ok..

 

Well it runs and runs great. I was installing the coil when I read ur message so I tried the wire that was on it and i had spark so I put everything together and took it for a ride, completely different machine! As always thank you for your help and advice!!!!!!!

 

What the devil did you do different?