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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.
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By Joe Brenke
View File 1998 Kawasaki Bayou 220 Owners Manual
1998 Kawasaki Bayou 220 owners manual
Submitter Joe Brenke Submitted 10/29/2018 Category Kawasaki ATV
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By Ed Zeppeli
Hi all,
I picked up this quad after the previous owner couldn't get it going.
The issue is that I can't get it to fire at idle or at all.
I've...
- replaced plug. Decent blue spark. Also tested with spark tester inline.
- rebuilt the carb. PO had already bypassed vacuum lines from petcock. There's fuel at the cylinder
- Checked compression with new gauge. reads 190 psi
- cleaned all contacts I could access.
- am currently jumping with car battery. Solenoid jumpered.
- checked cam timing at TDC and adjusted valve lash
- put gas directly into cylinder to see if it will fire at least momentarily
Motor turns over well. Plug gets wet.
Motor may fire once or twice but smokes through exhaust a bit as if it's trying to fire or combusting.
This leads me to suspect timing. As mentioned I checked the flywheel mark versus cam marks. Perhaps someone has been in there before because I can't find a 'T' on the flywheel but there is a very visible paint mark which aligns with TDC position on piston. Possibly a slipped flywheel/woodruff?
Is it possible that if it had seen previous repairs, that the timing could still be off? I'm reluctant to dig into the flywheel/stator area if there's something else I could have missed but all signs point me to that area. Would a bad CDI cause spark timing to be off?
Anywhere else to diagnose incorrect spark timing?
I've scoured these forums and elsewhere but I'm posting just in case there's something I've overlooked up until now.
Thanks very much for reading!
Warren
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By Brittany Jones
Yes I just got a 1998 polaris xplorer 400 4x4. Ran fine after hauling then died. Cleaned carb and put new fuel filter, hose, and new battery in. Starts 3 out of 10 times but will only run for a short time. Any suggestions?
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By Brian Simmons
The battery was gone when I bought the 90 .There are 7 wires 3 red 1 white ,1 black , 1 green and 1blue . 1 red and 1 white are connected with connector like it`s suppose to go to the battery . I think it`s called an eye connector it`s round and has a hole in the center . So it can be bolted to the battery and the same with the black wire the one black 1 has a connector on it that looks like it goes to the battery . that leaves me with 2 red wires , 1 green wire and 1 blue wire !!! Can anyone help me with a diagram of how the wiring goes to the battery on my 2002 Polaris Scrambler 90 ??? Please help me with this my e-mail address is [email protected] Pl
Please help me with this . Thank you , Brian
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By weblex
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.
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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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By Jacob Jackson
What are your honest thoughts on Polaris sportsman's? More specifically the 570. Is there anything to look out for? I purchased one a few weeks ago and was wondering what other people thought.
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By r97f1504x4
View File 2018 Polaris Sportsman Touring 850/1000 Owners Manual
2018 Polaris Sportsman Touring 850 SP / XP 1000
Submitter r97f1504x4 Submitted 02/03/2019 Category Polaris ATV
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