Stumbled onto this site looking for some help/answers for my atv. I searched around but need a little more info.
I have a 2003 400i 4x4 auto. It starts up fine and runs great for about 20-25 minutes then starts running rough, sputters, backfires and dies. If I let it sit for a bit it starts up fine and runs again for about 5 minutes, then the same thing. Does anyone have any access to the manuals so I can do some meter checks on the coil, voltage regulator, stator, etc.? I'm pretty sure the problem is electrical, just need some assistance. Sure looks like a lot of knowledgable folks around on this site, I hope someone can help me out.

 

Check the fuel tank vent first. Pull the hose off the tank and blow thru it. If it is clear, blow into the nipple on the tank, it is easiest with a short piece of hose. If those are clear then chase the expensive stuff. This sounds exactly like a plugged vent. It could be electrical, but you will really need a spark tester to start the troubleshooting.

 

Thanks for the quick reply Bear 4570, both of those are clear. Another thing I noticed is that my fan is not coming on anymore like it use to. I jumpered out the fan and it works fine. Tonite when I was out on it, it started acting up again. This time when I wiggled the harness going into the stator the problem cleared up and it ran fine. When I got back home I let it cool down some, started it back up and I could get it to die only if I played with the harness directly where it leds into the stator housing. Could it be something to do with the stator harness? Anyway to check the stator out.

 

Sounds like you have a bad stator, at least the wires from it. I don't have the amnual for an '03, only 2001 and 2005. The stators (magneto charge coils) are different.

 

Thanks Bear, I'm gonna start tearing into in the a.m. Hopefully I can just get away with repairing the harness without replacing the whole stator. I let you know how it works out.

 

Well I tore into it finally and I found 4 wires that were bad. I soldered the wires that were bad and put it back together. Went for about an hour ride and feel that the problem is fixed. Quad ran great and no issues. However I didn't quite get the gear shifter lever aligned up, i have all 4 positions but just not where they are suppose to be.

What is the screw for that is at the bottom of the gear assembly for the speedometer? I decided to take it out when putting it together and when I pulled it out, some threads came out also[img]i/expressions/face-icon-small-disgusted.gif[/img] I've only noticed a couple of drips from it but it really p*ssed me off. It must of been assembled that way because I've never touched it before. Oh well, just wondering what the screw was for and thanks for everyone who helped. [img]i/expressions/face-icon-small-smile.gif[/img]

 

Super, Glad you found and fixed your problem and cheaply too.