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I'm working on my brothers' 2002 Suzuki Vinson 500 . It sat for a few years before I got into it. I'm concentrating on the carb - I replaced orings, needle, etc. and soaked jets, bowl and anything that I could get off the carb that the solution wouldn't eat. I also removed the tank and flushed it with hot water - it's clean. The gas cap innards rusted away and the tank had a lot of rust and water in it before I cleaned it. I replaced the gas cap and installed a new fuel valve because the screens were broken in the old one. The bike will run but spits and sputters and backfires. If you "open it up" it falls on its face and stalls - but starts right up. Here is a link to an exploded view of the carb: Ohio Honda Yamaha Motorcycle ATV Dealer - J & J Motors - Kawasaki Suzuki Scooter Utility vehicle, parts, accessories, apparel
Can anyone point me in the direction of the problem? It may still be a "clean carb parts issue" . My problem is that the parts list doesn't identify the parts to a degree that I understand. If you said" look at the pilot jet", I'm not sure which jet that would be....See what I mean? It'll run very good if I remove the air filter and cover the opening with my hand and part my fingers a little for the air to get in. Any help is greatly appreciated.
Thanks in advance, Jim
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
Got a 04 Sportsman 500 that wasnt running- owner said it needed a stater and a new battery. It ran rough (been sitting out in the weather for a while). A friend and I started by adding a new battery and it would start barely with the choke and his hand over the air-filter. I decided to install the new battery in the holder on the side. we had it on the rack because the old on was still in the bike. I tried to be nifty by turning the battery to put the terminals in an easier spot to get to, but forgot to reverse the cables too. In a sentence, I reversed the positive and negative on the battery like a dummy. When we discovered my mistake and corrected it, we turned on the bike, but the display did not light up and the key did not turn on the starter. jumping the solenoid worked the starter, so we thought the solenoid just burned up when I reversed the pos and neg... new solenoid and no difference. what have I burned up? Also, the shifter does not seem to do anything in the trans. it slides back and forth like its stripped in the trans. any help would be appreciated!!
I think the biggest issue right now is the electrical.
Hey guys, figure you guys would have some helpful direction or answers.
So, 05 Sportsman 700 carb, new carb, fuel pump, new plugs, new air filter, new everything I can think of that is usually the running issues. Starts up fine, seems to run fine, but if under load, two people, or even one person, up a hill, or pulling a drag chain for the driveway, it starts to cut out and sputters and loses all power, until I back off on the throttle and just barely try to let itself catch itself and then I can take off again.
I am going crazy trying to figure this thing out. Other than that, the quad runs great. Parents bought bran new, just used around the property, 5000 miles on it. Any ideas???
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By Mark Walters
Hi guys. First post, hope you can help. As above 1991 Honda fourtrax. Starting, running fine until a few weeks ago. Used primarily to put my ski boat in the garage (put 2" ball on front). Any way, had just backed boat into garage, turned off to crank trailer wheel down, when I went to restart got nothing.
No neutral light, no headlights, no reverse light, would not turn over when start button pushed. It would crank and run when I jumped the contacts on the start relay. While running the neutral light will come on, although it is dim and flickers. Reverse light on when running and in reverse.
What I have done to this point:
1. Used jumper cable to ground battery (-) terminal to engine block thinking ground wire from battery to engine may be bad. No neutral light, no start.
2. Applied 12 volts to start relay. Got a loud click like it was making contact. I didn't have the battery/starter cables connected to the relay, but I am assuming it would have cranked at that time.
3. Disconnected neutral switch wire. Grounded neutral switch wire with jumper wire. No neutral light, no electric start.
At this point I am thinking ignition switch vs broken wire in the harness going to the neutral switch (due to dimness and flickering when running).
Any and all suggestions to help track down this issue are appreciated.
By Connor Tuftin
I have a 1988 300 Honda FourTrax, All wheel drive.
My brother and I were fixing up this quad. We put a brand new battery and fuses in and it was running fine until we put the quad into reverse. As soon as it was put into reverse all of the electrical cut out and power wasn't making it to the head unit anymore and both of the brand new fuses popped. We figured there might have been a short from the starter or solenoids, but they are all working properly. At this point we don't know where to start looking for where the short could be. I'm just wondering if anybody has had the same issue or knows of similar issues that could cause these electrical shorts?
By Steven Workman
So I have a Honda Fourtrax 300 year 1988. The ignition doesn’t start it with no sound. The headlights won’t turn on. It has a brand new charged battery, fuses are good, oil is good, gas is good, reverse is rusted, it shifts good, won’t jumpstart but when you try it will turn over, it will start if you jump the solenoid give it gas and spray starter fluid on the breather but it won’t stay on long but will stay on for the little time it does by itself. I don’t know what’s wrong and I need help!
By Arnold Schimberg
I have 88 4trax FW , it has a booster circuit
In the cdi control fed from a leg in the alternator.
MY Honda service manual says you will get no spark without this circuit on this model.
Can someone explain a little about this please ? Thanks
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