Quantcast
Jump to content

  • Join Today, It's Simple and FREE!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

Recommended Posts

Working on 2002 700 sportsman in shop. Engine has no power. Pops and backfires at 1/2 throttle and above. Carb is clean. Good fuel flow. Checked stator output with DVA. 19v on charge coil. 6v on pulser. Would like to know if this is cdi related.

Share this post


Link to post
Share on other sites


Handlebars. The throttle have wires going into it? If so open it up and you will find the rev limiter.  Try to separate the wires and see  if that clears things up.  Sometimes on the polaris bikes the rev limiter starts acting up.  

 

 

Share this post


Link to post
Share on other sites

don't think rev limiter is in handlebars. That would be throttle safety switch. I umpluged black wire to handlebars eliminating all switches up there

Share this post


Link to post
Share on other sites

Double check that its not a separate set of wires in the handle bar. As well as trace them to be sure they are disconnected.  Or do what I did. Reconnect  everything and then open the top cover on the throttle and run the bike. While is backfiring etc separate the contacts on the throttle control and see if it clears. Only reason I’m pushing this theory is it happened to my bike and solved the problem.

 

Share this post


Link to post
Share on other sites

Switch is not problem. What do you know about cdi box with built in coils?

Share this post


Link to post
Share on other sites


Could be the cdi but not my first choice.  I would do some testing first. Maybe test some devices like the  pick up coil for starters. Also the stator coil maybe do an ohms test as well look at the secondary ignition coil.  Sometimes the spark breaks down after the engine is hot or in your case maybe it’s happening right away.  There is a tool to see if  the spark is breaking down while the bikes running. 

Its a useful tool. 

 

I know we are talking about electrical items are you sure it’s not a foiled plug or a fuel rich condition happening ? Or timing ? 

Lisle 20610 Inline Spark Tester https://www.amazon.com/dp/B0002STSC6/ref=cm_sw_r_cp_api_i_ebj1CbF42SW39

489AEB9C-68EB-49CC-AC36-240F0FAAD8F1.jpeg

Share this post


Link to post
Share on other sites

Have that spark tester. New plugs, old ones looked ok. Made no difference. Gave you cranking voltages of charge and pickup coils in first post. Went thru carb with fine tooth comb. Polaris updated that ign system in 2004 or 05. Timing is on speck. Had flywheel off to check for damage, (loose magnets, Burnt coils) looks good. At a loss

Share this post


Link to post
Share on other sites

I read that you gave  the cranking voltages on the first post.

NOT cranking voltages.Ohms reading on the coils like a said in my last post. This will at least put the coils in spec.  This should also be done on the rectifier/regulator. 

I remember a similar topic on this and it turned out to be a pick up coil that was the problem. Is was a hair to far from the flywheel and on higher rpms is started to act up causing this problem. It was in the Polaris forum. I would not be surprised if it’s the same thing.    

It was a while ago but should still be in the topics section of that forum.  

Maybe @Ajmboy or @Admin can help us dig it up?

I believe it was the gap between the pick up coil and flywheel. There is a spec limit on that.  

Share this post


Link to post
Share on other sites

sounds to me like a badly adjusted carb.  does it get better or worse as the motor gets warmer?

Share this post


Link to post
Share on other sites

no change as motor warms up. What would I look for if cam or lifters were bad. Going to try different carb but think I am spinning my wheels.  

Share this post


Link to post
Share on other sites


Did you check the gap on the pick up coil ?

Your going to feel like your spinning your wheels and it gets frustrating. Keep calm and it will get sorted out. Some problems are more in-depth then others.  Process of elimination.  

Share this post


Link to post
Share on other sites

Sometimes get puff of smoke out of carb when clicking starter. Some times eng kicks back when trying to start. timing is about 9 degrees at idle. Book says 8

Share this post


Link to post
Share on other sites


You may have to take a look at your valves and rocker arms etc. It’s possible somethings going on in there.  The back fire and puff of smoke out of the carb all though sounds like a timing thing but I guess it can’t hurt to have a look at the top end to make sure it’s all proper and valves are opening and closing the right way. 

Share this post


Link to post
Share on other sites

I had the exact same problem with mine. I replace the cdi and changed it over from DC to ac using a conversion kit I got from a shop in Canada but still had the same problem. A friend came over one day and we got to talking about it and he was like can I take a look, sure why not. He took the carb out and drilled out the brass plug for a needed that was underneath of it. Made an adjustment to it and put back in. It ran like it was new. No problems since, 70 mph, and felt like it even had a little more get up and go from a dead stop. Hope this helps, I could have saved a lot of money and time if he would have stopped over for a beer sooner lol.

Share this post


Link to post
Share on other sites

Most people don’t know that the screw even exists. And then try to tell someone to drill out the carburetor??? Lol we have had this discussion before and there’s so many more times this will probably come up again.  It’s like finding a hidden door! 

Share this post


Link to post
Share on other sites

I never knew about it. And sure will never forget about it now. He said it had something to do with CA laws. I guess just in case it ever found its way out there but I don't know for sure. 

Share this post


Link to post
Share on other sites

I’m sure it has to do with some dumb law but hey at least they make it so you can drill it out.  Good luck brother and ride safe.  

Share this post


Link to post
Share on other sites


Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By Summer Warren
      Hey I just recently bought a 2002 Kawasaki Bayou 220 when you shift it jumps a lot and while it’s riding it it’s jumping as well but won’t stay started when you let off the gas Could somebody tell me what could possibly be the problem? Thank you
    • By Christopher Middleton
      I was given a "Go-Kart" its an old Carter brothers dlx150 but the engine is not the same that came with this Kart. I am trying to ID it so i can look at getting some parts for it. the pictures attached are of the motor and the only ID marks on it. I am thinking its some sort of 200cc from the 1980's does anyone have a better Idea? I am really trying to get a rebuild kit for the carburetor. on the carburetor is  Keihin 63 AA YKT

    • By tyler250rrocks
      i have a lt250r that has a over sized carb on it. is it to much
    • By JacobSlabach
      got 7 atvs off CL recently for a good price.  one of which is a yamaha warrior.  anyone know where the vin is printed on this bike?  Haha good place to start as I do not know year or size yet.  The former owner says needs exhaust ans and clutch work.  he said it ran fine until the clutch cable broke and then I couldn't get the new cable adjusted right and it would grind gears.  things I see:  clutch cable locked up again, no brakes, carb leaking (green with algae around the bowl and has gelled gas stalagtights on it), aftermarket exhaust melted the airbox so I need something different and a new air box.  I would like the use the current exhaust if I can but I have a feeling its a redneck fix as it looks like there is an ace bandage holding it to the exhaust pipe (its an aftermarket slip-on exhaust), so I'm not sure about that- lets get the bike running first.  also, battery (looks brand new, what a shame) is dead, 0 volts.  Otherwise, bike looks to have not been wrecked, and plastics are ok (it sat outside under a 'tarp' for 3+ years since it was run last).  any tips and advise on where to start first would be awesome as this is my first clutched bike (manual).
      the clutch is my main concern- I've never rode a clutched bike so I dont even know what its supposed to feel like.  lol I'm spoiled on my automatic polaris 
    • By oxidized_black
      View File 1988-2002 Kawasaki Bayou 220 Service Manual
      5851c4c6b5ba7_1988-2002KawasakiBayou220ServiceManual.pdf
      1988-2002 Kawasaki Bayou 220 Service Manual
      Submitter oxidized_black Submitted 12/14/2016 Category Kawasaki ATV  
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...