Gwbarm

Agreed!

👍

So true! Nothing like easing through the woods on ATV calming relaxing and peaceful.

Great reasearch! Thats good to know that it will work because they looked different and like you said everyone said that the Kodiak and Big Bear were different. I thought it was Odd that the Big Bear 400 was the only model that didnt have an aftermarket CDI available.

What was going on that you had to adjust the shift linkage so much with only 13 miles on it. You might have overadjusted it i would try going back toward the factory setting not all the way back but just in that direction and see if anything changes. Adjustment may be so far out that it never gets out of neutral or the machine thinks its not out of neutral, and not letting it shift.

Thats great news, and aftermarkets are hit and miss some work very well. I have one on a suzuki now that is working very well, idles perfect runs perfect, but i dont go full throttle and act the fool like i used too, that is when you notice the difference.

I would also recommend using the OEM carb.

Is the timing chain in tact, it must be broken for that to happen

You should be able to tell if the valves are hitting the piston with a bore scope.

Does it stop hard or just get harder to turn, if it stops hard something has come loose inside the engine, it could be a loose rod bolt stopping it but still attached enough to roll over the piston, just one senario, something could be wrong with the clutch gear stopping it, i would try taking off the side covers first and see if everything is in tact there and see if any thing is going on there, regardless good score. I think you will definately get your 10 dollars worth.

I would check to make sure you are getting a good fuel supply to the pump and also to the carb, but from what you describe it sounds like a partially clogged main jet. The capped port appears to be a vacuum port for running a vacuum operated petcock, if you dont have that on your original carb just keep it capped.

You dont have to post meaningless posts. Although i have seen that done, you can post to the threads that are active and share your knowledge or ask questions regarding certain things being talked about. Or even if you see an older post that you have some input to share, do that. You can even start your own thread about something that interests you and you would like to know more about. Admin would just like to see a little participation, not just hop on get the manual and then never come back.

Thats a big project.

I use manuals.lib for hard to find manuals, it sounds like a good project, good luck!

The Rhino is a great ride, i have always liked them, never got the opportunity to own one.

It sounds like it may have been rebuilt recently.I would also check the piston ring end gap it should be between .0020 and .0024 thousands.

These are all good points Mech, if the aftermarket one has a wiring diagram that would be great then you can figure it out. If not the manufactuer may supply you one. Just from looking at the wire colors, blk/white usually goes to stop/run switch, brown generally for accessories, but you dont have a red so it might be the power in wire, blue/green pickup coil , black for ground, and that leaves green for the coil, but they are generally orange, but these are all just guesses. I am not that familiar with wire colors on Arctic Cat, and aftermarket CDI wire colors are all over the place, they very rarely match the original harness.Even with a plug you sometimes have to change the pins to a different location to get it to work.

If the new CDI is aftermarket and the old one has no plug and the wire colors dont match, i dont have a good solution for that. I would say trial and error but thats never a good thing.

I agree on the TRX90 those little 90cc engines are great, maybe a little small for teenagers , but perfect for 10 year olds just learning to ride.

Thats interesting a Can-Am clone, a little suprised to hear that.

I havent heard of that carb sounds interesting, im going to have to check it out, thanks for the tip.

Yeah havent heard from you lately, hows it coming.

What was the problem with the coils, no spark or weak spark, if you have a good blue spark your coils should be Ok you may have to look at it at night to check that out. I would then try adjusting the mixture on the carb they arent always perfect.

If its smoking that much it sounds like you may have a broken ring, im surprized it runs, have you checked the compression.

It looks like a fairly nice quad, very capable, but i have never seen one.