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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
Hey all, I recently bought an 01' Sportsman 500 HO from my brother in-law that he's had since new. It runs awesome, just has 2 slight issues that I am addressing. 1st issue is fuel dripping out of overflow. I did some searching around and saw that the O-rings in the carb wear out and allow fuel to leak, so I replaced both the Orings inside the carb. This didn't fix it and still leaking which leads me to believe the float needs adjusted, I'm just not sure on correct way to check and correct this. 2nd issue is no speedometer. Also in researching this it appears to be Hall Effect/speed sensor. I'll be ordering one of those to replace, which sounds like a pretty straight forward process. I guess really my only reason for the post is to get some help on the gas leak issue. Any thoughts? Other than that, I love the bike and really enjoy riding it. Thanks in advance for any replies.
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.
I have a 02 Warrior i am trying to build a wiring harness i have looked in the manual and i am confused... the pick up has 2 wires. W/R W/G The source rotation coil has 2 wires. One is Red other is white/blue. The manual shows the the white and blue wire connected to the w/g right after the stator... so why is these 2 wires connected? Does not show w/b wire at cdi
i have looked at many options with no luck if someone has a 2002-2004 warrior and can take a pic of the wires and location at cdi i would really appreciate it. Thanks
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