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post #1 of 6 Old 03-06-2018, 10:33 AM Thread Starter
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2002 Polaris 500 Spark Issue

I had the dreaded flywheel issue. Replaced the flywheel and stator as both were bad. Installed a new coil and cdi as well. Still no spark. Any ideas? This thing is giving me hell.
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post #2 of 6 Old 03-06-2018, 09:39 PM
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ATV: 09 Thundercat
2009 Mileage: 300
2008 Mileage: 2000
Is the battery 100% charged? Have you tried to start it with jumper cables from car battery?

I know on my cat the spark signal comes from a pick up coil that sits next to the stator. The coil tells the cdi when the piston is top dead center and sends a voltatge pulse to spark at the corret time. Have you checked this?


Is there power to the starter coil?
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post #3 of 6 Old 03-07-2018, 08:58 AM Thread Starter
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I know the battery has a good charge. It cranks the engine over pretty dang fast. I changed the pick up coil when I changed the stator. The service manual I have is shoddy when it come to checking the ignition system. I know the coil itself is not getting power. I also checked all of my grounds and made sure the coil is grounded and everything checked out ok. There has to be something I am over looking. I checked the wiring and found nothing wrong. Could it be a safety switch or something. I am at a loss.
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post #4 of 6 Old 03-07-2018, 01:29 PM
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Originally Posted by azazel_18_2 View Post
I know the battery has a good charge. It cranks the engine over pretty dang fast. I changed the pick up coil when I changed the stator. The service manual I have is shoddy when it come to checking the ignition system. I know the coil itself is not getting power. I also checked all of my grounds and made sure the coil is grounded and everything checked out ok. There has to be something I am over looking. I checked the wiring and found nothing wrong. Could it be a safety switch or something. I am at a loss.
Does the popo have a tilt sensor? Basically a kill switch that keep the vehicle from starting if the bike gets flipped. I know my cat has one near the tail light.
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post #5 of 6 Old 03-08-2018, 08:16 AM Thread Starter
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Interesting but I have no idea what I am looking for :/
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post #6 of 6 Old 03-12-2018, 03:55 PM Thread Starter
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I have dug through the wiring harness and wiring diagram and here is what I have found. There are 2 plugs on my CDI. One set goes to my brand new stator so no worries there. The second plug has 3 wires. One black which is ground and the wire is grounded. The other is a blue/White which goes to the coil. This wire gets no power as we speak even though it should. The other wire is an orange/white. Followed it up to the switch and found no issues. Found that the orange/white wire is the power wire for the cdi and does have power to it at the cdi. Sounds like my cdi is fried. What do you guys think?
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