compression tested good -------------- no reply from numerous e-mails to Ricky Stator , they don't even answer the phone , gave up on him , I wouldn't recommend Ricky stator to anyone , good price on a internet purchase , no support ------I am convinced the problem is one or more of the electrical components of the ignition system is breaking down from heat , I say that as now if you let the bike sit over night and walk up to it and hit the button it will start up and run great for 3-5 minutes then doesn't pop or sputter , just shuts down , it's not a fuel vent or fuel flow problem -----changing the stator changed the problem , it would do a one spark then nothing , now after it heats up it will do 5 weak sparks in row and then 2 or 3 revs , with this pattern over and over , let it sit over night and it will fire up and run good for a few minutes then shut down -------- a part bike with all good electrical parts to swop out one at a time might be the easiest way to figure this problem out

 

Resistance test on a coil may show good,but can breakdown internally from heat after it warms up. Shops that have an ignition coil tester that puts a load on the coil can confirm if it's good or not,but coils are the cheapest of the elec components and plenty available. Same thing on the cdi. They can break down,but most manuals just say to replace with a "known" good one as there are no good cdi tests. Here's one place,but you can check ebay on parts prices also.Polaris ATV CDI Boxes, Coils & Voltage Regulators | ATV Parts | MFG Supply
Even Amazon has good prices that some overlook. Plus not normally many bad reports on Ricky stator. Have used them in the past with good results.Even had one stator accidentally wired backwards,but they sent a new one overnight. Don't think it's stator related since it at least starts now with the new one,but more than likely a coil or cdi braking down when hot. Plus you can recheck the stator pulse coil gap to the flywheel and see that it's no more than .040 from the raised tab on the flywheel. The bracket can be slightly "tapped" inward to decrease the distance. May or may not help.

 

I got a CDI off e-bay for my 99 Sportsman 500 , it arrived and I found the one sent to me has 7 wires and the one on my bike has 8 wires , the one wire missing is a green wire , the old cdi has a three wire plug which is where the green wire is , the new cdi doesn't have a three wire plug ----- any ideas on this one

 

May have gotten the wrong replacement cdi. Schematic shows the red wire,green wire,black/red to be the cdi charge coil wires from the stator.Oem is a tad expensive ($243).Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse But Mfg Supply shows to have the replacement for your #3085639 oem cdi for 49 bucks.IPO6004 - CDI for many 95-02 Polaris ATVs. Stock Performance. | ATV Parts | MFG Supply I've always been a little leery on after market cdis,but this one shows your oem part # and shows the green wire.

 

Thanks for the quick response , what a mess , it just won't end , one thing after another -----your right , I trace the green wire back into the brand new stator wiring harness --- do you have any idea what the extra wire does , and why some have it and some don't ----- Thanks

 

Just changes in stators and cdis and connections,some even mid year. You have to know which one you have as some generic stators and cdis won't work.Here's the info on the the cdis from MFG Supply,some go by vin#,either before or after a certain build date if there were electrical changes.From what it lists,this cdi should work.

" Some years and models use our IPO6007 CDI module depending on the ATV serial number. Look carefully at the replacement CDI connectors to make sure it matches your ATV connectors."

The following ATVs use our IPO6003 or IPO6004 CDI module
2000 Magnum 500/HDS (though serial number 00-1960)
2000 Scrambler 500 (through serial number 00-004729)
2000 & 2001 Sportsman 500 (through serial number 00-29082)
2000 Sportsman 6x6 500 (through serial number 00-1898)