Recoil can get more torque and speed at the stator exciter coil than the electric starter can,but it still should have spark if the starter and battery are ok. Even though you have a new stator,cdi and coil,I'd still check the exciter coil resistance that's listed at the bottom of your post and also the coil resistance specs. Some aftermarket Chinese electronics are hit or miss as far as quality.Plus if you didn't clean the inside of the flywheel magnets or if it's damaged in anyway,that could be another problem. Retrace your steps. If you need a manual that can go a little deeper here's a cheap one.1997 Polaris Trail Boss Service Manual PDF Download

 

Thanks for the link to the manual, I have a Haynes and it's very limited. The stator specs are good according to the manufactor. Ignition coil I'm not sure on but I have several different ones that I have tried. I CLEANED the magnets really good I didn't see any damage to the magnets but I did notice that in between the magnets there are some clips or something that looks like clips that are in bad shape?.

 

Clean the inside with carb cleaner,blow out an residue and trash and see if any change. May be as simple as that.

 

Ok I will do that tomorrow and let you know.

 

I went ahead and pulled the flywheel, cleaned with carb cleaner, it looks real clean and free of dust. Saw no damage. Reinstalled, and test. Still no spark with electric start, but have spark with recoil.

 

If you're sure the stator ground wire is secure,should be tied in to the other grounds at the lower coil mount,then check the resistance on the exciter coil black/red to brown/white wires and see what you read.

 

Below is the specs from the stator manufacter, I am within range of all specs. What I am worried about is source one on Polaris stator is 120 ohms. Is this ok since it's a different manufacturer. This manufacturer is at 992 ohms. They said it is for a 1997vPolaris trail boss 250.



Here are the specs for our stator. Your results sound good at 0.9
Is your multimeter at 2000k?

Wire to wire resistance :
Alternator : Yellow to Yellow/Red = 0.04 ohms +/- 20%
Source 1 : Black/Red to Brown/White = 992 ohms +/- 20%
Ground : White to Brown = 0.2 ohms +/- 20%

 

ALL Polaris 250 Trail Boss and Trail Blazers used the same pick up coil from 1985-2006 when the 250 was finally dropped from the lineup.. All readings on the wires are 120 ohms. Where you got this stator/exciter coil from along with its specs I have no earthly idea.. Even the 300 and some 400 2 strokes used the same pick up coils.Here's a few examples of years that the pickup coil 3084922 was used. https://www.ebay.com/sch/?_nkw=3083422%20Polaris Saw the stator you have from RM stators. Does show 992 ohms,but bet it's a misprint.Probably more like 192 ohms which would be more in line with the oem exciter coils. IF in doubt you can always pick up a cheap exciter coil on ebay and solder in place. OR return this stator(if returnable) use your old stator lighting coil with a new pick up coil from ebay. Obviously somethings wrong as this is a simple system as far as getting spark to the cdi.

 

 

Same thing as far as what RM stators show on their exciter coil also. 992 ohms. Somethings wrong somewhere if not a misprint. I'd trust this one from the Chinese maker Caltric over a used one from ebay. https://www.ebay.com/itm/STATOR-Fits...-/290916865478