If you have to just cut the old wiring,it's junk anyway and route the harness up along the frame tube and secure after all the connections are made. Attach the ground wire to the small plate cover the wiring to the pulse coil. Pulling the flywheel doesn't affect timing,it's keyed to the shaft for timing,the new one is the same. Mount the new stator like the pics show.

 

new stator has ground wire connectors on both ends1 stator boot that I attached to the back of stator mounting bolt and one that connects up underneath headlight.old stater just had ground wire connecter under headlight. it was pre connected at stator.I will be back in garage in 30 minutes to look at this again

 

Back on the road again!! For my model I had to use 2 jumper harness wires as shown in picture in step 15. I had to dig into the above wire loom to find the red wire male connector which instructions failed to mention. Also, there is a replacement regulator kit for the the replacement regulator which had additional instructions. I had to actually cut on the nose of the front plactic to install it. Great project!
It looks like I'm going to have to do some work on the front axles. They seem a li loose. Plus 1 front and 1 rear outside boot. I may need advice when I get there.
Thanks, Old Polaris
Croc

 

Now hopefully no more electrical problems. The red wire does fool some people as you have to dig for this one that's tucked up into the harness.Instructions are a little vague on this one! Good luck!

 

Hey Old Polaris, I was looking back at posts and where you mentioned to connect ground wire to small plate covering the wiring to the pulse coil. I completely brain farted and left the ground connected to the nearest stator bolt. Will this be ok?

Thanks

 

As long as it's grounded to the engine and clears the flywheel that's good enough.If in doubt move the ground wire underneath the pulse wire cover plate bolt. Item #1.http://www.cyclepartswarehouse.com/f...2003&fveh=5618

 

Okydoke. Have a great weekend, oh ya your retired, your weekend never ends!

 

Oh no,not a constant weekend. I have 5 days that I do what I want to do, which a lot of times is nothing,THEN comes the weekend. Time for really goofing off

 

Just wondering what ignition systems are in a o6 sportsman and 08 sportsman. Were there alot of problems with these year of machines.

 

There's a mix of different electrical components on the later models. Kokusan ignition systems along with Bosch ecu modules on efi machine. Later carb model had some problems on the pdm modules that controlled charging ,the fan and power to the coil.They could short out.Efi systems had their own problems with the small sensor wiring and connectors.