 Let me show you what this bad boy can do. Hey guys, welcome back to another episode of Titanium Man Garage. And today, I've got a new project. I believe this is a 97 sportsman. And it's got no spark issue. So now these older models, it's not all plug and play. It's got your circuit board, what looks like a big rat's nest. Don't let that scare you. It's actually not bad. Once you're able to read what the board says and what everything plugs into, it's actually not that bad. In my past videos, I've always said if you got no spark or one spark, no spark. It's always the black wire to the CDI. Plug that, and a lot of times you'll get spark. Then it'll let you know if it's your run stop kill switch coming down on the handlebars or if it's your CDI. So here's the CDI box right here. That was all plugged in right here. And as you can see, there's nothing plugged in there. That's an alternative ground. Your main ground bar is behind these wires all up here. Brown is plugged into it. I did that, I disconnected the black wire, got no spark. I replaced the coil because my coil wasn't looking too good. That will emit spark to your spark plug. So if you look here, I wasn't getting any ground here. I grabbed my tester. So what I did was I moved everything over here. And then I've also got my grounds right here. This factory that they go right to the rev limiter. On other models, there's a bolt that goes underneath the coil. I don't have it in. What I'm going to do is I'm going to move these over to here and round everything out over here underneath the coil. Because I think that's a better ground. I think Polaris started doing it this way putting the ground wires right here. I don't like it because you're putting it on aluminum plate and then it's screwing into the metal frame. So I want to make sure I got a good ground and I'm going to move that over there. And I started doing some tests and there's actually a pretty good video. This guy had gone through and shows how to test staters, your pulse coil. Because that would be my next step. What I also did do is you've got your throttle safety kill switch. I disconnected that just to bypass any issues. No power going to it at all. So I can rule that out. I've ruled out the run stop kill switch. The CDI box I actually changed. I robbed it from another one. And then the coil, I've actually put both coils in and tested them. And both spark plug coils up here, they're good. So that brings us down to the stator. My first thought was it was the pulse coil. So if you've never pulled your stator off, this is your pulse coil. When your flywheel spins around, actually let me show you the flywheel. This is one really clean flywheel. There's a little plate that sticks out there. It's casted into the flywheel. Every time that passes the pulse coil, right here, every time it passes it tells it when to spark. It could be one or two things. Either this is an adjusted rate, or there's a short in the wire. I tested that with the old meter and I wasn't getting any reading on that. I did pull this cover off originally, and I did find a small break in the wire, but it was still making contact. And then I noticed this. You can see that. It looks like it's burnt. So I haven't been able to actually trace down what the issue is if it's the stator or the pulse coil. So I'm going to replace the whole thing. Got a stator, a pulse coil, everything came with the whole wiring harness. Brought this off of eBay. So yeah, that should do me good. It's for the right model. I'm going to throw that in and see if I get spark. So the next time you see this thing, I'll have everything grounded at the coil instead of on the rev limiter. I'm thinking right up here I might find a way to ground this to the frame so I got a good ground for the other black wires that go to it instead of putting it in that side panel. Or I might just leave them there. I don't know, I could do both. But I kind of like to leave everything original, so I might try to ground that out. And then I'll swap the stator out. These three bolts come out. And then this mounting plate to keep your wire down will come out. And a screw here and a screw down here. Pulse coil will come out. I actually have the stator plate loose so if the wire is tucked underneath there I can get to it. And then disconnect all my wires and replace it. Alright, here we go. I got it disassembled. I think I'm going to post a video about being assembled. There's actually a ground wire that goes behind. This thing actually looks kind of fried. If you look through here, I'm going to hold up the light. That's all barbecued. It's all melted here. Yeah, it looks like something got hot. Then there was a split in the wire. You won't be able to see it in the camera but right there where my thumbnail is, right here. So I'm hoping replacing this will do the trick. Okay, here we go. Now I disassemble it. There's a ground screw that goes here. On the new stator this wire is really long. I should really cut it and bring it down but I don't have an end like that. So I think I'm going to just try to tuck it out of the way and hope it works. I like to hand start the threads. Not that I strip something out. I don't like the way this looks. I might end up cutting it. I'm going to go to the hardware store and replace it. Just remember where that gets positioned. So you put it back in the right spot. Then all of this will land up. Right now I'm just going to snug one of the bolts up so I can make sure I've got everything else lined up before I tighten everything down. That might get caught in the flywheel. If you get an aftermarket stator, you might have to cut that shorter. I'm not going to do that right now. So for video purposes, I'm just going to show you how to assemble this and I'll probably end up cutting that shorter and getting that to fit. I got that loose. It's not tight tight. I'm going to run this plate in here. I want to try to do this without pinching the wires. To leave it loose, reposition your wire where it should be. So I'm going to tuck that in last. What I'm going to do is put the pulse coil on and make sure you've got it in the right direction. Alright there, hopefully you guys got a little better view. With this aftermarket, the wires are a little longer so I had to tuck this behind here. I'm actually going to take this plate back off and tuck these in really nice. Put the plate on because there's little tabs in the way. Tighten these down and then there'll be an adjustment later on. There you have it. I'm going to pull that plate off. Tuck these wires in nice. I'll throw the flywheel back on. Alright guys, I got everything back together and I hooked up the spark plug. Put a new plug in and I got a spark. Then I threw the spark plug back in the engine and it wouldn't fire. So I'm getting a one spark no spark condition. So I got multiple issues. One spark no spark. So the stator was bad and that brings me back to the CDI. Either the CDI is bad or the kill switch. So I'm going to replace the CDI box because that's usually the common cause of one spark no spark. I'm going to try one other trick. I'm going to follow the black wire up and disconnect it because if it is the kill switch that should bypass it. Let's see what happens. If you're gas leaking it's because I'm draining the tank right now. Disconnect the black wire and she fires. So it tells me one of two things the CDI box or the kill switch. I'm thinking it's the CDI box. But I haven't started this thing yet so I'm going to put that plug back in and see how she fires. There you guys go. She runs like crap. Hasn't been running over a year and a half. Disconnected the black wire for the CDI. Smoked it a little bit. It needs to get adjusted. Blowing white smoke. They thumbed the throttle a little bit. The throttle cable stuck. I'm going to probably have to replace the throttle cable or it's possibly the choke cable that was not adjusted properly. So the guy had put in an aftermarket carb which I'm thinking is the culprit. Just because it's blowing white smoke doesn't necessarily mean it's a head gasket leak like you saw earlier. It's blowing white smoke up. I'm thinking the guy has this carburetor adjusted wrong. It runs like crap. If I close the choke it dies. If I keep her wide open she runs but races. I've got multiple issues. I've got to adjust the throttle cable. Adjust the choke cable. Possibly replace the throttle cable. I do have another carb I might try. I might just throw that in there because this has been sitting for a while so who knows it's stuck in it. Might need a good cleaning. I've got to part some machine out back. I do have another CDI. I'm going to give that a shot. Hopefully that solves my issues. I'm actually going to pull a spark plug and I want to see if it's black. My gut tells me it's going to be black. If it's black means the carburetor is running rich and it's not coolant blowing out of there. If it's wet and white or if it smells like coolant then I've got a head gasket leak. It does look like this has some work done to it. I'm looking at the gaskets and I mean this engine is pretty clean. So I don't know if the guy ripped it apart or rebuilt it or if it's the original engine it's only got 1,500 miles on it which I'm hoping it's the original. I'll have to do a timing adjustment check the just check the head. If you want to get rid of your little spark issue that's just my little jump pack you're beeping. It stinks in here. Smells like oil and gas burn. If you want to get rid of your no spark, one spark or absolutely no spark that's how you replace the stator and I will be replacing the CDI and checking the kill switch because it's either one of the two I disconnected it and just to let you guys know if you do disconnect the black wire going on to the CDI sometimes it will not shut off. So just so you know I hope you guys enjoyed this video I gotta get out of this garage that stinks in here. Hope you enjoyed this video and like always till next time.