Thanks for staying with me. Sorry for late reply, been busy fixing other broken stuff.

OK, here goes:
Flywheel is exactly correct replacement, same part #, FF95.
Black wire from limiter disconnected.
Black wire from kill switch disconnected.
New stator and wire harness installed(aftermarket, not OEM)
New trigger pickup installed, part of stator harness.
Was not able to check gap for trigger coil. Couldn't get feeler gage in there. Not much adjustment available as holes for mounting are round, not slotted.
New spark plug gapped at .025".
New coil.
New CDI box.
All coils have been ohmed out and appear to be acceptable.

Crank it over and no spark whatsoever.

Now what?

 

Checked that the replacement stator pick up coil white and white/red connector matches up and wires not switched around? Plus will it start or try to start with the recoil starter or have you checked to see if you have spark using the recoil only? Could be similar to the problem on a lot of 500s that have had this happen and was pick up coil related.http://forums.atvconnection.com/pola...ml#post3155476