Hello everyone. I am new to the forum and I am looking for some help on a 1998 sportsman 500.
I picked this wheeler up for a good price since it didn't have spark. The previous owner claims to of replaced the stator, CDI, coil, starter, and battery. I took it home and verified the no spark. However I did find that I would get one and only one spark as soon as I let go of the starter button. I traced all the wires and I didn't find anything suspect, so I broke out the multimeter and checked the stator and coil. Nothing jumped out at me when I checked the stator or coil. So I hooked up a spare CDI box and I still had the same issue. The only way I can get the results to change is to unhook the black wire from the CDI. If I remove the black wire I get no spark at all? The black wire seems to hook into the "hub safety switch". Can the hub saftey switch go bad? Anyone have any suggestions what to try next?
Stator & coil results:
Coil primary side: .2-.7 it varies (my meter hunts when I check this circuit) book spec is .3-.5
Coil secondary: 6350 ohms book spec is 6300
Capacitor charge coil:
green to black/red 468 ohms book says 446
green to red 4.2 book says 3.2
red to ground open and mine is open.
check the pulse controler out side of the flywheel and push it closuer to the flywheel it fixed my 97 scrambler 500
DING! You are correct sir. I took the recoil/stator cover off and pivoted it closer. I couldn't get the bolt to line up so I just made it closer for a quick test and I didn't bolt it down . It now has nice blue spark. I will have to file the assembly so it can sit closer and have the bolt hold it in place.
Now I will have to clean the carb and replace all the fluids. The unit has been sitting for 2-3 years. Thanks for your help guys.
98 sportsman 500 no spark
