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Hey guys, new here, but haven't found ANY answer to my specific problem on a Suzuki dedicated ATV forum, so here's to hoping!
I acquired a 95' Quadrunner 250, 4x4, (LT4WD) for practically nothing with no spark. The PO had tossed in a used stator which didn't fix the problem... so I went all routes (though cheaply) to narrow down the initial problem of no spark.
Plug, coil, CDI (caltric) and stator w/pickup (caltric) were purchased and installed. And it RAN, but bogged horribly and would not rev past 1/4 throttle.
I checked fuel flow, vacuum lines, all the normal stuff, no issues. I decided to check the valves and cam... well, there was one problem. The cam was 1mm under the lowest spec in the manual. So, in-came a new cam, Stage 1 Hotcams... also threw in a new set of shindy valves, lapped them, replaced the valve seals, and the timing chain.
Back together again (w/stock airbox and new oiled filter). Now it idles even better, still boggs at 1/4 throttle, but will rev past it if you hold the throttle open for a second. Ahaha... success!
So I was able to ride it above 1/4 throttle once I had momentum... could shift through the gears, all was good as long as I kept it over 1/2 throttle. Took a long enough ride to break in the cam properly at least so I won't have to worry about that.
Now, I start fiddling with the carb. It's clean as a whistle, stock, with stock jets (new replacement Mikuni jets). Same problem.
I start thinking, maybe this is fuel related and the bike is having an issue transitioning from idle jet to main jet... so I LOWER the needle by raising the clip 1 spot. Now it revvs up in neutral with no bog, but it boggs about the same trying to ride it. So I move the needle down again with the clip on the top slot. Better, but still has a bit of bog at 1/4 throttle.
The last bit of advice I got was to ditch the CV carb... so I sprung for a brand new Mikuni VM30-83 round-slide. Bolted it up, blew into the vacuum tube to fill it with fuel (no vacuum port on this one) and she fired right up... but there is still a bit of bog, it's just masked by the fact that I'm not waiting for the vacuum diaphragm to open.
So I feel like each little step brings me closer, but not perfect. I'm now wondering if this is still in-fact a carb tuning issue (I have some jets I can fiddle with and maybe lean-out the idle jet a little.) OR if the cheap-a** Caltric Stator/Pickup is what's causing these issues.
I have a 95' KingQuad with 400 miles on it... like new.. runs like a top... I've tried both the stock QR and the Caltric CDI boxes on it, and it revvs up and runs like a champ.
The only unknowns between the two systems are the carb, and the stator/pickup. My next step in troubleshooting is to rip apart the King Quad and test it's CDI on the Quadrunner... but considering there is no change to how it runs I doubt it will lead to a solution.
HOWEVER... I tried the stock CDI just recently after running the Caltric this whole time, and the bike runs like garbage. Hardly idles, and won't rev up at all. So, that is my one smoking gun telling me that it's either the pickup coil or the stator itself.
Has anyone had a problem even CLOSE to this? I can't image the carb would be causing this many issues, especially going to 2 different ones, both with stock jetting to OEM, and exhibiting the identical symptoms... the only change is when different CDI's are plugged in, or when the needle valve leans out the mixture.
Also, I checked the piston, rings and bore when I had it apart and they're like-new... no scoring, rings are loose, cylinder is still round and has honing marks still int he bore. Stock piston, stock bore size and it has 160psi compression. Battery is brand new, and I've tried 3 different R/R's, none of which change any symptoms, but slightly vary the charging voltage by .2-.5 of a volt depending on which unit. Also tried a new coil which changed nothing.
ANY help would be appreciated. Too much invested to not get it running right.
By John Ford
i ordered a keihin carb for my 07 trx 90 and it fits nicely but the new cable they sent is way too long and i can't make it work. the old honda cable cap [that fits on top of the carb] is too small to fit. the keihin cap is approx 3/4 or 19mm. honda cap is more like 1/2 in. the keihin has a rubber boot on the cap where the throttle cable goes through . i don't know how to find the right length [most cites don't give the length]. i'm not sure how cables fit into that boot and do i need to add the length of the boot to the cable? the old honda cable is 28 inches total, but the cable movement is only approx 2'' which would not be enough to reach the actuator block on the keihin. looking to find a throttle cable compatible with the keihin. any help, please.
By colin james
View File 2005 Polaris Predator 50/90 Sportsman 90 Service Manual
This is the factory service manual for the 2005 predator 50cc and 90cc, Sportsman 90cc. Download all the chapters for the complete manual or just the sections you need.
Submitter colin james Submitted 04/06/2019 Category Polaris ATV
By Roy Anderson
I have a 2002 Suzuki LT-F500F, and am a first time atv owner. I rode two wheel bikes for many years, and now, two months in to being a new at owner, am just not enamored with the thumb throttle, and I’m wondering if anyone has tried a conversion to a typical twist grip throttle as found on all motorcycles? If so, how do you like it?
By Fred Colby
TPS on Polaris SPORTSMAN 500 efi 2007 shows as bad original part number is 3140173 bought the replacement part it came in as 3131705 the diameter of the ring on the face is 26 mm the original is 18 mm any thoughts on how this "factory" replacement parts fits as i cannot get it to go in?
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By Tyler Autry
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these are what i have in my collection ... always looking for more
1985 - 1995 Polaris All Models Service Manual
1996 - 1998 Polaris All Models Service Manual
1996 - 2003 Polaris Sportsman & Xplorer 500 Service Manual
1996 - 2003 Sportsman 400 & 500 ~ Xplorer 500 Service Manual
1999 - 2000 Polaris All Models Service Manual
2001 Polaris 90 Service Manual
2001 Polaris Scrambler 50 ~ 90 Sportsman Service Manual
2001 Polaris Sportsman 500HO Parts Manual
2001 Polaris Sportsman 500 Parts Manual
2002 - 2003 Polaris Sportsman 600 & 700 Servive Manual
2002 Polaris Sportsman 700 Service Manual
2003 - 2005 Polaris Magnum 330 Service Manual
2003 Polaris Predator 500 Service Manual
2003 Polaris Predator Parts Manual
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2003 Polaris Trail Boss 330 Service Manual Part I
2003 Polaris Trail Boss 330 Service Manual Part II
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2004 Polaris Predator 500 Owner's Manual
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2005 Polaris 400 & 500 Sportsman Service Manual
2005 Polaris 700EFI Owner's Manual
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2005 Polaris Sportsman 400 Parts Manual
2005 Polaris Sportsman 500 Parts Manual
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2005 Polaris Sportsman 800 Twin EFI Parts Manual
2006 - 2007 Polaris Outlaw 500 Service Manual
2007 Polaris 700 800 800x2 EFI Service Manual
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2009 Polaris Sportsman 300 & 400HO Service Manual
2009 Polaris Sportsman 450 & 500X2 Service Manual
2009 Polaris Sportsman 500 Service Manual
2009 Polaris Sportsman 6x6 800 Service Manual
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Visit the Polaris Service Manual Section: https://www.quadcrazy.com/files/category/7-polaris-atv/
Problem: The ATV starts and runs at idle perfectly. But as soon as I open the throttle, the engine starts to slow down until it stops. On the attached video you can hear the sound of how it works: see video below
Prehistory: there is a Polaris Sportsman 500 1998, which for about 1.5 years stood in repair, including also replacing CDI with one taken from the same ATV. Finally, the vehicles were on wheels, traveled several kilometers and overheated - forgot to fill the antifreeze Came back home in small moves. The next trip started well, but after 10 km there was a feeling of a small drop in power (even as the vehicle got warm completely) but still drives. Next trip - the situation is repeated. The next test of ATV through time and a huge loss of power from the very beginning. The engine sneezes, does not want to go more than 5 mph.
What has been done: the carburetor has been replaced with a new one (inexpensive, $ 40), a new spark plug, a new ignition coil, the engine head has been removed, the piston is in good condition, valves were corrected - but the problem was definitely not in them.
Ignition control unit is suspected. Who faced similar? Please help in solving the problem.
Thanks in advance.
By Ashton Crawford
Hello everyone, i have 2000 Polaris Trail Blazer 300 I’ve been stumped on for weeks. I’m having a lot of issues starting the quad. I cleaned the carb spotless because I thought it was a carb issue and bought a new fuel line because it wasn’t getting fuel. The carb gets fuel perfectly fine now but it won’t start. The spark plug I a little worn out but it’s good enough for just one start. The only time it does “start” is when I spray starter fluid into the carb. But it never stays on. It’ll start for a bout a second then just die out immediately even if you’re giving it some throttle and the choke is on. I have no clue what I should do. If you need more information, have questions, or have any slight idea what the issue would be and how I could resolve it. Please reply ASAP. Thank you.
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