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I just bought this quad about a week ago. I am pretty mechanical and technically inclined, however I know nothing about this thing yet. I do have the service manual though.
Now to the main problem: The best I can explain it is that it sputters at full throttle. You can actually let off of the throttle to about half-way and it goes faster. Also, when I first got the quad, it only had this problem every now and then. Now it does it at every full throttle press.
Let me tell you what I know about it, which ain't much... It has been pretty well modified. I can't compare it to stock since I haven't been on a scrambler in years. When it takes the gas, it screams. It has a different higher performance head and piston (top end just rebuilt), a clutch kit, pipe, reed, and several other mods that he told me about.
I know nothing about this thing or where to start. I'm guessing it has something to do with fuel intake. I changed the fuel filter but it didn't seem to make a difference. I ran in totally out of fuel and put a fresh tank in. I am running 87 octane, surely that can't be it.
First check the air filter and the air intake tube to be sure the tube isnt colapsing(should have a wire or spring in it to hold it open.Next take the secondary clutch apart and check the ramps.Be sure to preload it the right direction.
Next unplug(it should be the black wire )on the rev limiter.
2002 500 Scrambler-White Bros pipe,HPD airbox/carb mod chain tensenor and shock covers,TEAM roller secondary clutch,custom primary clutching ,WORKS struts,and much more SOLD
2003 330 Trailboss-stock excepet for EPI pink primary spring and Aaen blue secondary spring(gone with wife)
2001 400 Sportsman traded for a CJ5 Jeep
2004 Victory TC Cruiser
1972 FLH Harley (my pride and joy of 20+yrs)
Thanks jumbofrank. I saw that thread but it didn't seem to have a solution, plus I was guessing the 450 may have been a 4-stroke.
I will try drlang's first since it's the easiest, lol. If that doesn't work I'll move to ftwlh's or other suggestions. Thanks a million guys. I've got some experienced Polaris mechanics lined up but until then I'll play around with it.
I never even thought about the muffler before. Take out the clean-out plug. It can be REALLY stubborn on old machines. If you have to, use penetrating oil and a pipe wrench. If you wreck it don't worry. It's just a bolt that you can get from the hardware store. Crank up the quad and rev the engine up several times to blow out all the soot that the spark arrestor has been catching, maybe for the last 11 years. Shut it off and put the plug back in.
Hey i just got a 2000 scrambler400 2x4, the top light cover is missing i was wondering if you knew what is was supposed to be? the oil netural and reverse lights are there. the actual light works bit there is no symbol on it to tell me what it is. any ideas?