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.

Chad Dickerson

2004 Arctic Cat 400 very hard start random dies

Recommended Posts

I am goin nuts here! I have a 04 400 air cooled 4x4 , I'm a atv,car,truck,mower mechanic for yrs,just sayin. Ok it cranks and kinda fires now and again then after 5 min of cranking and stopping itl start if u touch throttle itl did then u start all over! If u let it warm up sumtimes u can throttle it up other times it just does! Just depends on it? When it stays running it runs awesome,no problems except it just does randomly like u shut key off? Sumtimes itl start right back up others itl do the no start thing! IV put new plug,adjusted valves and hot tanked carb? I'm at a loss here guys! Please any other ideas? I don't think it's anything to do with flywheel? It's not the auto it has a hi low reverse lever on left fender and foot shifter? Help please lol

Share this post


Link to post
Share on other sites


I would do a compression test.  See where your at for starters. Maybe a leaking head gasket, rings etc. 

Second I would check the intake boot that connects the carb to the engine for cracks. Then look at the quality of the spark and make sure it’s strong and that it’s not breaking down after it gets warm.   

And just a dumb question, have you checked the fuel that it’s not bad and you have a good flow going to the carburetor?

Share this post


Link to post
Share on other sites

It only has 400 miles on it, it was rode very little but started and kept up by atv shop , then new owner got it ,he was using it everyday for bout 6 months then this started one day while riding. I'm sure compression is like new but I'll check for sure in morn. , I looked at carb to head intake boot and it's in great cond. He was using it alot and uses seafoam every other tank but I did clean carb just cuz.i have looked at spark when tryin to start and it's a white blue hot, changed plug anyway, and when it does itl start right back up. Most times its just that sumtimes even after warm itl start up but if u touch throttle itl just die, only sumtimes? Itl idle for a long time then just die? It's crazy now I'm going crazy! 

Share this post


Link to post
Share on other sites

Lol take a deep breath.  There is an answer and it’s just going to be a process of elimination. You have to go over things again to be sure. I know it sounds repetitive but it’s worth it.  

What did you set the air fuel screw at ? 

Check that the choke is working and opening and closing properly and not getting drawn closed as you rev the engine.

Look through the wire harness to see if any rubbing against the frame is happening where wires are intermittently hitting the frame, take the plugs apart on the harness and add dialectical grease on the plugs and put back together. 

 

Share this post


Link to post
Share on other sites

Feul screw is at 2 turns out, choke or enrichener is working properly, I will go over wording tomorrow and report findings. Thanks for helping it's drove me nuts for 3 days now and I have to get it finished just never ran into this before. Thank u

Share this post


Link to post
Share on other sites


One thing to try is while it is idling, turn on your headlights low and high beam then try to give it some throttle. If it runs better, shut off the lights and take a meter and measure the voltage on the battery. Should not be above 14.5, if you give it throttle and it rises, the regulator is not working and it will mess up the CDI and cause a loss of spark. It is also possible the voltage goes low and will cause loss of spark. A bad regulator will cause these issues as well. Its an easy test with a meter.

Though the symptoms are acting like the carb is not cleaned properly. You could also have some junk in the tank from it sitting and it got sucked into the carb.

Older cats fuel lines were also not made to handle the E10 gas that we use nowadays, the inside of the fuel line could be breaking down and causing junk to be sucked into the carb. With a machine that is now 15 years old, I would replace the fuel line, then add an inline fuel filter while your at it.

Wire rub through was not known to be an issue with 2004 cats, and with only 400 miles I would think that is not likely at this point.

Mike

 

Share this post


Link to post
Share on other sites

Thank u Mike I'll try that as well. Really really appreciate your help and the rest of the ideas to try from others! Thank u will post results this morn 

Share this post


Link to post
Share on other sites

Ok I found a prob, I took plug wire cap off to check fire, it fires bout five times then stops fireing for several crañks then fired again for a bit then stops? Over and over? That's why itl act like it's gonna start then not? Any ideas? 

Share this post


Link to post
Share on other sites

Check the battery as I mentioned above to make sure its not weak, that will cause loss of spark. The coil could also be weak, that is an inexpensive part to replace.

Have you downloaded the service manual for the machine and schematics?

Mike

 

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 AimlessMoto
      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 Jade Dockery
      Hi, my names jade 25. Western NC Mom of two young boys. Who wouldn’t have a fourwheeler if I hadn’t picked up learning about what it took to repair a China 110 quad. That lead to a passion of atv repair. 5 months in and I’ve learned quiet a bit and interested in helping and learning how to fix my current Honda 87 250x that’s been through some hands as well as a china 50cc dirt bike that’s been rebuilt on the outside and soon learn how to replace valve stems and piston rings. 
    • 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 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 Thomas Brooks
      I know...I feel stupid for asking.  I find it impossible to use the thumb throttle with my thumb when I have the bars turned full right. I have to reach across the top and grab the throttle from the front with my fingers. It isn't very smooth and I can't help but think that there must be a technique, mod or adjustment for this. How do I get past this?
      Thomas
      2017 Polaris Sportsman 570 X2
  • Similar Tagged Content

    • By axleshaft1
      dead  electric   2004 arctic cat 400 4x4 auto      wire was coroded off man in harness in front of  regulator      two  red  power wires  where they join  into  one   was pulling hair out on this     start removing  tape -  low and behold  problem solved 
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...