Ok I have a 2003 Sportsman 700 like mentioned in the title. First off it has already had the ignition upgrade done to it. Ok now the other day I went to back it up out of where I park it. Backed it up and then it just died. I figured I was out fuel so i left it and forgot to turn the key off. Come back its dead of corse. Swap out the battery from my wife's 600 put mine on the charger put fuel in it and then it will start but wont run. It fires like once then instantly dies. Ok so I check the carb its getting fuel its good and clean, next I change the spark plugs... Well after I have changed the pugs I n longer have any spark at all. Any ideas? Any help? I have run out of ideas.. Obviously it could be the stator, coil, cdi, etc... Don't really wanna just throw money at it. Thanks a lot!

 

Grounding seems to be the major problem that people had on installing the Kokusan kits. Could be the cause of your spark problem.Make sure the ground wire termination screw under the front panel is tight,plus also the ground wire that mounts under the pick up coil protection plate along with double checking all the additional connections from the new system that may have come loose.

 

I checked the one under the front panel and all the connections. I haven't checked the one under the pickup coil yet gonna try that tomorrow. Weird thing is that the kit has been installed for a long t9e and this is the first problem I've had.

 

Hopefully it's just the ground on the stator plate. Seems like this is the most common area for problems and the instructions don't tell you exactly where to mount it.

 

Well just got home from buying a flywheel puller... Pulled the flywheel and the stator is covered in oil. I guess the seal decided to go bad.... Pretty sure thats my problem....

 

Sorry to hear that as the engine has to be split to "properly" install the new flanged seal that fits in a groove in the cases. I've heard of "fixes" to where different type seals were used,but haven't seen one or heard whether they held up..Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

My mistake! Was concentrating on the clutch side seal! If it's just the seal behind the stator leaking, you just have to remove the stator,impeller and pull the outer cover off. This outer flange seal just knocks out and a new one in. Plus best to replace the water pump seal and small oil seal why you have the cover off. Better than having em leak when you replace the cover back on.

 

Yeah I actually just finished pulling it all apart. It actually has a new water pump seal and and the other oil seal however since I have it apart i think I will go ahead and replace them again. I actually got 2 of the water pump seals when I bought my last one so have it on hand. Just need to get the flanged oil pump seal and gasket. I am hoping the oil didn't completely short out the magneto but with my luck it probably did. At least I don't have to reassemble everything to test it out.

 

Clean the stator and flywheel up with electrical contact cleaner and blow it out with an air gun.Keep your fingers crossed and give it a try..