My 04 450 runs fine for about 15-20 minutes then dies. It re-fires with the clutch lever in, rev's up about 3/4's, but when you try to take off it sputters and dies, when re-started it's the same thing. After it sits for a while it will run fine. Another 15-20 minutes and it does it again. Seemed like it was starving for fuel so I checked the fuel system: tank, petcock & carb. Also the gas cap vent and air filter all are clean and working fine. I think it's an electrical issue: CDI, Carb Electrics... Etc... Anyone have an idea?

Rude Dog....

 

Start with changing the plug. It's easy and cheap. From there I know the '04's had problems with the Stator. Sometimes you could resolved the issue by running with the lights on.

 

I dont think its a stator issue cause if i remember correct they overcharged the battery and caused it to prematuraly go bad. I would check your valves because if it does it when it gets warm, the metals expand and would cause the vavles to tighten up to much if they aren't adjusted correctly.

 

I changed the pLug, so scratch that one... Could be valves I suppose? Odd with the clutch lever in, it runs better until you start to release the clutch lever... Oh, one thing I remembered.. I repleaced the clutch cable.. I don't know if that would have any effect on this? Their is wiring on the clutch perch...

Rude Dog

 

the wiring should be just so you can start it in gear as long as the clutch is pulled in. check your fuel lines and make sure they aren't close to the exhaust and any other place too hot. could be that the fuel is getting hot and vapor locking.

 

Change the coil. I just had a '05 in my shop for the same thing and it seemed to be fuel related at first but after working on the stupid thing for 2 days I changed the coil and that was it

 

Hmmm... Fuel lines, I doubt that's it, but I'll double check. I will check out the coil... I have access to some electrical parts, so I'll try swapping a few around to see if I can figure it out. Thanks for the reply's!!

Rude Dog...