This is awesome! Soldering tip... put tip of iron under your wires so the heat rises up to the wire and apply solder from the top. Of course the way you did it works too but using physics should save you time. :) Thank you for your efforts! Great video!
Great video, and others. I have a 2004 polaris sportsman 500 ho, replaced everything at one time now I have no spark ,no voltage to coil wire.replaced cdi box and connector, any ideas?
Thank you for this video Mark! I was seeing rusty water boiling up out of my pull starter. The gasket was nonexistent when I pulled off the coil cover. Would you recommend wire brushing off the rust? Should I apply some sort of oil or grease as a rust preventative?
Thanks for posting this. I am currently working on my sisters 'no-start' 500 polaris. I can't say how much I hate these machines. Besides the no-start issue this machine overheats, and toasted one pull cord already. Neighbor has one too parked by his house rotting away because it keeps breaking down. These are early 2000 model machines. I have an 89 and 91 Kawi Bayou, and a late 80's Suzuki quad 'something' that though abused as hell still run and go perfect. You couldn't give me or even pay me to own a Polaris.
39knights I’m beginning to feel that way.. bought a 04 700 a week ago, ran great when I bought it. Now out of he blue I have no spark, that’s on top of all the other broken things I knew needed fixing. I have had an 89 Yamaha Moto 4 and still have an 09 Yamaha kodiak. Rode the hell out of them and they’ve never let me down. This is the first Polaris I’ve ever had and I haven’t even been able to ride it yet
Hay Mark, great video very thorough . Like to see someone that takes pride in there work. I have a question on the raised part on the outside of the flywheel that triggers the pick up coil is that supposed to be magnetized
nice video, thanks. I am trying to fix a 09 sportsman 400 HO . I have rebuilt carb,new fuel pump, cleaned lines ,vents everything fuel related. It runs like a top and whenever it feels like it , starts sputtering stamering slight back fires. shut it off , it may run great again may not. I am starting to think electronic ignition type problem . Gonna take all the front plastic off, what a nightmare on this model, and check connections from coil up to electric ignition box. I am gonna check the pickup coil out now also after seeing your video . I had the cover off and the bendix and all the wiring looked good, but I will check coil gap out and condition of it. The machine only has 60 original hours on it . Sat for years. Are there slots on the pickup coil so you can adjust the gap on the flywheel like on a lawn mower tractor/ I didnt see any when you installed it.
Thank you so much for this video!!! My coil was fine but a chunk of broken pull cord had widened the gap about 1/4”. Reset the gap and my machine purrs!!
were you getting any spark at all or was it just weak or one spark ,Mine I have spark only right after getting off the ignition button thanks for any info and what manual do you use good vid too
What would be your first thought about a Wildcat 1000 with new starter, battery, Pulse Coil, Stator and plugs that cranks but won't start? Problems started when the dashboard displayed codes relating to the Pulse Coil and sputtered to a stop.
***** Perfect. Thanks for taking time to reply. Huge help. I just checked my resistance and I have the same problem. read 36.4 ohms at red / white and white. ordering pulsar coil now.. will get the service manual as well.
Hey man quick question. I have a 04 500(first half of the year) so it should be about the same as the 03. My gap for the pickup coil is darn near 1/8in away from the flywheel. And it doesnt seem to have any way to adjust closer. How were you able to adjust the gap?
Mark where did you order the parts from? Have an 02 with all the same problems except it was my ratchet ear that came apart in the pull start assembly and destroyed my pulsar completely.
I got a no trigger coil and put it on but when I was putting it back together I seen a little wear on the magnet drum in the key way. Do you have any advice?
Great video. I noticed I have one quick spark when I turn over the engine from the off key position but there is no continuous spark after. Hoping this solves my prob. On the white/white red test I got .529 k ohms. My problem happened as soon as I landed from a jump. Bike immediately turned off. Then was backfiring. Checked woodruff key on flywheel but that was ok. I did jump timing but fixed that and still not starting. Checked spark and as stated before, only have one immediate spark when turning key from off position but no continous spark. Sorry for repeating...Cancel
I wish my screws backed out as easy as yours. My screws are very tight. I got one out but the other one acts like it wants to break off and the screw driver is starting to slip and strip out the phillips screw head. I might have to pull the flywheel to get a better angle on the screw head. Phillips screws were a bad idea for the trigger coil.
i have trouble with my 500 6x6 sportsman 2007 atv , i went out to start it and found out the battery was dead so hook up the boaster cable and notice that the rad fan was on with the key off which killed the battery. the odometer lite up but now its blank, the stator did turn but did not kick out to start the atv no power to anything else can , when i turn the key nothing happen, i did change the control module but no difference ,can you help, where should i start to fine the problem, thanks
haviving a problem with mine seams to be same ..have not tested..traded a vehicle for it.started fine and drove great..next day was a bit difficult to start but once warmed up ran fine.. then while riding engine died and would not restart engine cracked but no start..any ideas to check ?
I have 1997 Polaris sportsman 500 when I push the start switch I get one blue spark then nothing, it's only when I first hit start button I get one spark, do you know what I can do to get more spark so at will start?
My 2013 sportsman 400 wont start...its just clicks once and that's it..the battery is new, all the power/lights work....I think its the starter or the solenoid. How can I test to see what it is? How exactly do I jump the solenoid to test it? Thanks.
Some help me I have 850cc Polaris sports man 2016 and it got flooded and the water went into the motar and I tried to turn it on while it still had water in it and it made it worst some one plz help
for the newbies next time can you show the actual no spark,did you just pull the plug and hold it to chassis ground and watch it as you turned over the motor
![HOW TO TEST A STATOR / WHAT IS A STATOR [step by step] GY6](http://i.ytimg.com/vi/VoXYzQ61tRM/mqdefault.jpg)
Affordable Multi-Testers on Amazon - amzn.to/2IYP7Mn
Polaris New OEM Circuit Breakers on Amazon - amzn.to/33F2nNV
Affordable Polaris ATV Manual on Amazon - amzn.to/32qoGH3
This is awesome!
Soldering tip... put tip of iron under your wires so the heat rises up to the wire and apply solder from the top.
Of course the way you did it works too but using physics should save you time. :)
Thank you for your efforts! Great video!
Great video, and others. I have a 2004 polaris sportsman 500 ho, replaced everything at one time now I have no spark ,no voltage to coil wire.replaced cdi box and connector, any ideas?
Thank you for this video Mark! I was seeing rusty water boiling up out of my pull starter. The gasket was nonexistent when I pulled off the coil cover. Would you recommend wire brushing off the rust? Should I apply some sort of oil or grease as a rust preventative?
good viedo man knows what hes doing
Thanks for posting this. I am currently working on my sisters 'no-start' 500 polaris. I can't say how much I hate these machines. Besides the no-start issue this machine overheats, and toasted one pull cord already. Neighbor has one too parked by his house rotting away because it keeps breaking down. These are early 2000 model machines. I have an 89 and 91 Kawi Bayou, and a late 80's Suzuki quad 'something' that though abused as hell still run and go perfect. You couldn't give me or even pay me to own a Polaris.
39knights I’m beginning to feel that way.. bought a 04 700 a week ago, ran great when I bought it. Now out of he blue I have no spark, that’s on top of all the other broken things I knew needed fixing. I have had an 89 Yamaha Moto 4 and still have an 09 Yamaha kodiak. Rode the hell out of them and they’ve never let me down. This is the first Polaris I’ve ever had and I haven’t even been able to ride it yet
Hay Mark, great video very thorough . Like to see someone that takes pride in there work. I have a question on the raised part on the outside of the flywheel that triggers the pick up coil is that supposed to be magnetized
Great video, how to adjust pickup coil closer to flywheel magnet or pickup?polaris 2004 500 sportsman.
nice video, thanks. I am trying to fix a 09 sportsman 400 HO . I have rebuilt carb,new fuel pump, cleaned lines ,vents everything fuel related. It runs like a top and whenever it feels like it , starts sputtering stamering slight back fires. shut it off , it may run great again may not. I am starting to think electronic ignition type problem . Gonna take all the front plastic off, what a nightmare on this model, and check connections from coil up to electric ignition box. I am gonna check the pickup coil out now also after seeing your video . I had the cover off and the bendix and all the wiring looked good, but I will check coil gap out and condition of it. The machine only has 60 original hours on it . Sat for years. Are there slots on the pickup coil so you can adjust the gap on the flywheel like on a lawn mower tractor/ I didnt see any when you installed it.
i UNPLUGGED MY SPEEDO THAT WAS NOT WORKING AND SUCKER STARTED RIGHT UP WITH GOOD SPARK DANG , GOOD VIDEO
very nice job, thorough troubleshooting/testing and neat installing of new pickup
Dose this all reply the same 2 stroke and 4 stroke
Thank you so much for this video!!! My coil was fine but a chunk of broken pull cord had widened the gap about 1/4”. Reset the gap and my machine purrs!!
were you getting any spark at all or was it just weak or one spark ,Mine I have spark only right after getting off the ignition button thanks for any info and what manual do you use good vid too
What would be your first thought about a Wildcat 1000 with new starter, battery, Pulse Coil, Stator and plugs that cranks but won't start? Problems started when the dashboard displayed codes relating to the Pulse Coil and sputtered to a stop.
Thanks for the video. Mind sharing the part number or where you got the replacement ignition coil? Thank you
Great job. I'm experiencing no spark and will troubleshoot starting with your DIY. What repair manual are you using and where did you get it?
*****
Perfect. Thanks for taking time to reply. Huge help. I just checked my resistance and I have the same problem. read 36.4 ohms at red / white and white. ordering pulsar coil now.. will get the service manual as well.
I need specs for my 500 magnum too, 02
excellent job!
great camera work
Hey man quick question. I have a 04 500(first half of the year) so it should be about the same as the 03. My gap for the pickup coil is darn near 1/8in away from the flywheel. And it doesnt seem to have any way to adjust closer. How were you able to adjust the gap?
Mark where did you order the parts from? Have an 02 with all the same problems except it was my ratchet ear that came apart in the pull start assembly and destroyed my pulsar completely.
Thanks for posting this.
hi what brand manual u using and is it the best
I got a no trigger coil and put it on but when I was putting it back together I seen a little wear on the magnet drum in the key way. Do you have any advice?
very very informative video..hoping to see plenty of more like these from you..thanks !
is your meter set to 200 Om's
Great job mark
Thank u so much it helped me out
Great video. I noticed I have one quick spark when I turn over the engine from the off key position but there is no continuous spark after. Hoping this solves my prob. On the white/white red test I got .529 k ohms. My problem happened as soon as I landed from a jump. Bike immediately turned off. Then was backfiring. Checked woodruff key on flywheel but that was ok. I did jump timing but fixed that and still not starting. Checked spark and as stated before, only have one immediate spark when turning key from off position but no continous spark. Sorry for repeating...Cancel
Pull the black wire connector apart, it's most likely the kill seitch
I wish my screws backed out as easy as yours. My screws are very tight. I got one out but the other one acts like it wants to break off and the screw driver is starting to slip and strip out the phillips screw head. I might have to pull the flywheel to get a better angle on the screw head. Phillips screws were a bad idea for the trigger coil.
Where can I get the "ignition system testing flow chart"
I have a magnum 500 02 Polaris, same issue, were did u het the coil n how much?
i have trouble with my 500 6x6 sportsman 2007 atv , i went out to start it and found out the battery was dead so hook up the boaster cable and notice that the rad fan was on with the key off which killed the battery. the odometer lite up but now its blank, the stator did turn but did not kick out to start the atv no power to anything else can , when i turn the key nothing happen, i did change the control module but no difference ,can you help, where should i start to fine the problem, thanks
Trigger coil the same as pick up coil?
haviving a problem with mine seams to be same ..have not tested..traded a vehicle for it.started fine and drove great..next day was a bit difficult to start but once warmed up ran fine.. then while riding engine died and would not restart engine cracked but no start..any ideas to check ?
+jimmyt568 sry..mine is a 2000ish sportsman 400 4x4
I appreciate the great video!
I have 1997 Polaris sportsman 500 when I push the start switch I get one blue spark then nothing, it's only when I first hit start button I get one spark, do you know what I can do to get more spark so at will start?
I've heard that with a one spark situation, it's a faulty on/off switch, not the key, but the switch. There's a black wire you can disconnect to test.
My 2013 sportsman 400 wont start...its just clicks once and that's it..the battery is new, all the power/lights work....I think its the starter or the solenoid. How can I test to see what it is? How exactly do I jump the solenoid to test it? Thanks.
Jesus Faith its the solenoid. That click is from the solenoid
@@supplykayo3049 probably cause the starter is bad putt 12v directly to the starter it should spin if not it's bad.
Some help me I have 850cc Polaris sports man 2016 and it got flooded and the water went into the motar and I tried to turn it on while it still had water in it and it made it worst some one plz help
What's the ohms rate
Where/How do I get a ignition system testing flow chart?
I have a 2007 Hawkeye 300 and have new trigger coil and it shows 514 ohms and it is only giving me between 5-6 volts and need over 10. And ideas?
what if pulse coil reads 120 ohms ?
david super good
If is 134.1ohm is that bad
for the newbies next time can you show the actual no spark,did you just pull the plug and hold it to chassis ground and watch it as you turned over the motor
How was you atv acting with a brokering plus coil
+Mark Jenkins this are a great video,it really helpt me ,,Jan G from Sweden
lot of them have defective bosch ecm, get me to a simple honda!