Just basic hand tools. 1/4" ratchet and extensions helpful to pull the recoil cover if need be. Good luck. OPT

 

ok so i am going up there this weekend very long over do but ive just been busy now my question is i wanna make sure i will be able to ride it when i get up there so what are all the parts of the ignition system that could make it not have spark and im going to call the polaris parts guy up there and make sure he has them on hand just in case i need them! just let me know! thanks

 

Pull the black wire from the limiter,if no spark, then pull the black wire from the cdi (kill switch wire) if still no spark could be the pulse coil or the stator area itself (dirty or burnt wires) . Plus check the coil wire for any cuts. Could be any of the above or could be something simple?Also an ohm meter to check out the pulse coil and stator connections if needed that go to the cdi. (don't have exact resistance specs,but pulser coil should be around 90-115 ohms(white and white/red wire going to cdi) stator wires for that year I believe were black/red and black?) around 440 ohms?Plus a new plug,good battery,plus you first mentioned the etc switch(you might pull the throttle cover and check for any corrosion plus 1/8" slack on throttle cable as mentioned). Hope you get it going and it's something simple! OPT

 

ok thank you OPT ! ill try all of that when i get up there friday afternoon and ill let you know what i figure out! and im sure i cant but would 400 ignition parts work to use for testing on my 500?

 

Just the ignition coil would interchange as the stator, cdi,etc would be different along with the connections for the most part. OPT

 

Ok I tested the pulse coil and I'm getting nothing and I tested the stator and I am getting 350
I have a new pulse coil and stator along with a new cdi and voltage reg is there any special
Way of installing it or is it pretty much hook up and go!

 

Just need a puller for the flywheel. Steering wheel puller or harmonic balancer puller with some long 8mm bolts along with some heat around the center of the flywheel while under pressure will work.Usually will pop off or you can tap with a hammer around the flywheel if its hard to remove. The rest of it is just plug in. Might be easier and less frustrating just to cut the old stator wires as they are usually routed tight under the gas tank and frame! Just route the new wires under the left frame and up between the fender into the cdi and coil area! Don't be surprise if pieces of the flywheel magnets may have shattered and caused the problem. Have had several do this and the replacement flywheel has been changed to sealed magnets.If flywheel is intact check the magnets out for any cracks or chipping. OPT

 

Ok I got everything installed and got it running again but the reverse override is messing up I have to use it in all gears! What could that be? And I'm still stuck with removing the roll pin in the front axle I need to replace the front sprocket and have been trying to get the pin out and I'm Starting to go crazy. what size is the roll pin?

 

Did you disconnect the black wire from the limiter? Plus do you have the throttle slack about 1/8" ? Just use a round punch the size of the hole for the roll pin,plus use heat if needed! Or if you have an impact driver just grind the bit down like I did so I wouldn't have to fight removing the roll pins! OPT

 

Ok I got the roll pin out but now the frames on the way of getting the sprocket off
Is there anything im missing from.what I've read you take the front right axle off and it should come off!