A guy brought his 97 500 sportsman over for me to work on with no spark. The guy said the dealer told him the cdi box was bad so I ordered one and put it on and tried it. Heres what happen with the old cdi it had no spark at all now with the new (used) one it has spark when you let off the switch just one spark. What should I look for? Thanks

 

Help

 

replace the stater, all ur tests will probly show the stater is ok, but probly not. leave the cdi that has a bit of life in it, and instead of using the key to turn it over, use the pull rope, will probly get a couple sparks out of it. the stater is partly shorted and only produces unough volted to fire the cdi once or twice. Ive seen this a few times on the 2001 -2003 500 hos.

hope this helps, let me know if it does.....

later
good luck

 

I will try the pull start but first I will have to fix it. It messed up on him about a year ago. I did a search on the fourms and some poeple was getting spark by useing the pull start. Thanks

 

Well I figured out why it has no spark. I took the recoil off (which didn't work) and found that the bolt that holds the little dog thing that flys out when you pull it has striped out and letting the dog thing come off. Well the dog thing got behind the flywheel and messed it up along with the stator. They are chuncks of magnet & metal everywhere. It also messed up the pickup coil. Now starts the quest for parts.