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By Dra O
posted a while back - it was running at one point - I have all the plastic shroud off - it's down to frame and engine now
-fuel pump: when line from petcock is attached, no fuel comes out other side to carb; the line to the carb is open (can blow through it); I thought when I cranked engine that the pump would spit out fuel on other side but it does not; I removed fuel pump and opened it up - diaphragm looks good - but internal areas had lotsa calcification build up - I cleaned this out and dried it good - the clear plastic pieces (?diaphragms) aren't broken - the spring w/ steel ball on end moves freely; am putting it back on tomorrow; but can anyone answer about the pump? isn't it supposed to pump fuel through it... to other side... to carb? puzzling
-along with fuel pump: I replaced petcock 3 weeks ago (gas tank had rusty fuel in bottom - cleaned it out prior to new petcock); when I turn petcock arrow NOT to on or reserve, fuel comes out of line; when I turn it to on or reserve, fuel doesn't come out; puzzling
-I don't know what's on back of fuel pump - it's a valve that has a hose coming out of it - looks like it goes to engine/carb - I haven't traced this out yet - what is it?
-can squirt gas on air filter and engine will run for 2-3 seconds then stop - fuel in top of carb (under diaphragm) does same
-it likely needs carb rebuild - will get to this - but something isn't allowing fuel to get from fuel pump to carb
-I THINK it has a mikuni model x carb - diaphragm is ID 26mm OD 68mm - hard to find inexpensive diaphragm, I guess because it's a model x
-last thing - I replaced solenoid due to old one clicking; I HAVE to be charging the battery or it won't start/turn over - battery just goes dead; but if charging, it'll turn over nicely; i'm guessing it's a bad battery
-any help appreciated - I've never owned an ATV before - inherited this beast from grandparent in-law
By Christy Miller
Need a wire diagram for
99 big bear 350 4x4 can anyone help I have no spark my roommate drove it ended up losing the battery and it grounded out a.wire in the middle of harness was burned to BEAR any suggestions ty
By Denis Lanthier
I have a 2004 Yamaha Kodiak, which has taken me to many remote places and hauled lots of game. I still love it after 16 years.
Lately when I go to start it using the starter, sometimes it clicks and kills the power in the display. Lights don't work, nothing works and I end up having to unplug the battery, wait awhile, and replugging the battery ends up giving the power back. Using the winch will sometimes kill the power as well.
Battery is new, all fuses are ok, I'm at a loss. I can start it with the pull crank and it will work and so will the lights.
Any insights or advice would be appreciated!
By Flipper Tiffany Roper Jones
hi guys I'm back again lol. Last year I bought a polaris 500 magnum had some issues we banged our heads together and Finally fixed the problem well im back. So it ran fine for a long while then just lost spark. So bought the same exact stator and pickup coil I bought b4 boom fired right up now the kicker runs for 7 sec then dies ok so hear we go with what I've tried
Gap in throttle good unplug black wire did it no go
Reflowted bowl just incase fuel stopped not and didn't fill up not it
Bought a new fuel pump stator pick up coil twice now
Bought cdi box nothing
But if you hold it half throttle when you start it runs for ever
So new spark plug new wire
Coil nothing ill take any ideas besides fuel even mention it
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By Chase Cook
Hi I just got an Polaris sportsman 500 4x4 ATV the other day. I got it real cheap but I started to go into it because it didn't have compression so I bought a new piston and ring kit for it and installed it, but now when I try to start it all it does is shoot fire out the exhaust or the intake of the carburetor. And a timing is top dead center.;I think I can't really tell another way if it is or not. when I put it together I made sure to piston was on top and the cam lobes where facing down where are the cam sprocket is facing up. It has gas and spark. It did start a couple minutes ago but it didn't stay running and now it won't start. Do you think the valve need to be adjusted more to close better?I'm fixing to try that out and if that don't work what is the problem? Also I made sure everything was together good and right and change the oil and changed out the radiator fluid.
By Brian Sosebee
I just rebuilt my 03 sportsman 400. Put everything back together added oil per the manual. Pinched off the oil tank vent line 2" away ran for 45 seconds then cut it off. Check oil level and it was still way high so I wasn't confident that it primed so I did it again. Checked again and it's the same. Remove the oil filter and it is dry. I did the procedure again and the same results.
I'm worried to keep trying this as the only oil in the engine is what I used to lubricate the parts when reassembling the piston. The crankcase was drained as well.
I Removed the oil tank and checked all the lines for obstructions and the screen filter and the vent hose and everything is clear. I even pulled a small vacuum on the oil tank while it was pulled off to make sure there were no leaks. The dipstick cap was on tight so I'm not sure why this thing is not priming.
Anyone have any suggestions. I thought about pre-priming the oil lines from the oil tank to the crankcase to hopefully help the system prime. I'd like to be able to add some oil to the crankcase to so I wouldn't feel so bad about running the engine for another 60 seconds without oil. I dropped just a little bit of oil in the spark plug hole to help condition the sleeve right now.
What do I do? Anyone had or heard of an oil pump failure on these. Btw oil pump is working fine before I did the top-end rebuild and the oil pump was not touched.
Please help!!! Thanks all for any and all help.
By cameron walton
Hi Guys, I'm a newbie but pretty handy with a DMM (controls technician). I have been fighting a junker quad i picked up as a project bike, was assured it would run if I replaced the battery and cleaned the carb. I replaced the battery, rebuilt the carb with a OEM kit. FIxed all my switches and foul played circuitry from the last guy.... So I could get it to start long enough to test the quad, it seems okay from a trans/engine point. However I couldn't get the carb adjusted to idle to save my life with the idle air screw or the thumb screw on the card for the slide. I took it to a friend who is much more familiar with yamaha and quads and he double checked my carb rebuild all was fine, he adjusted the float to make the fuel not overfill which i missed.
He pulled the air intake, got it started and couldn't get it to idle with or without air filter. We started looking at the spark plug (new) and he tested it with a spark plug clamp meter, tested good, pulled it and grounded and it had spark but he felt it was weak. I order a working used oem coil to try the easy things first. When I ohm out the coil on the quad with my Fluke i'm seeing .4 ohms on primary (ground lug to male connector) and 18K ohms on secondary (inside boot to ground lug). Seems like this forum is full of bear trackers so I'm hoping someone has some ideas to help me figure where to go with this. His thought was he know I ave fuel and he knows I have air, spark would be next. I have spark but possibly weak. Thanks
By jay rear
Hi im new to the site. I have a 99 sportsman 500. I has been sitting for about a year now. I bought a new battery for it the other day and now i dont have any power to anything but the winch. Any help would be great. I already cut the pouch and checked voltage on both sides of the circuit breaker.
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