Here's a link to an Ebay listing for a service manual,or try www.datamanuals.net.

http://cgi.ebay.com/ebaymotors...3A12|39%3A1|240%3A1318

I believe the choke voltage should be 12 volts, not 2. I don't think that's the proper voltage.

Happy Thanksgiving to you too.

 

I ordered the Reg/Rectifier and the manual is next. Thanks for the site info.

BoPo

 

Well, the Regulator/Rectifier replacement didn't do the trick. My baby is now in the hands of a dealer. I feel so empty......and alone.....

bopo

 

Let us know what they find!!!
We are waiting patiently LOL

BTI

 

Hey, will do. By the way, I just, by coincidence, found someone else who owns an '04 AC Quad who has been having a similar problem with the starting and stalling. His post is date 11-28-08. I sent him a response and will also let him know.

I asked the service guy is he has had this problem before and he says this is the first one he's heard of and that it doesn't fit in any scenario he's aware of. But then, that's why they charge a $75 Diagnostic fee..

 

Well BTI,

I just got my '04 500 TRV back from the shop this afternoon. Aside from replacing the Brake Light Switch, they had to deal with my unsual Stalling problem. I had replaced the Reg/Rectifier, the Elect. Choke, Coil, cleaned the carb, lines, air cleaner, and then I ran out of Ideas. It would always stall in the later hours of the day after I started it for a short time. Then it would not start again.

It had gotten progressively worse for the last 1.5 years.

They kept it at the shop for almost 2 weeks trying to duplicate the problem. They actually put 5 miles on it trying to get it to stall. It finally did what I told them it would do. It stalled later in the day and would not start back up.

The young guy assigned to my TRV practically tore it apart. He found a "Fluke of a Problem". The gas tank vent hose was knotted up in under the handlebar housing. The hose was removed and replaced with no obstructions.

They then tried to get it to stall again, No Luck.

I took it out in the snow and ice and drove it in 15+ weather for a couple of hours. Parked it up by the house and went snowmobiling for an hour. Then went back to the ATV. Started right up and ran great again for a couple more hours.

I have not been able to get it to act up again.., IT APPEARS THAT THEY FOUND THE PROBLEM (AND A SIMPLE ONE AT THAT)...

BOBPO

 

Glad they fixed it!. ( hope the bill didn't kill your Christmas spirit).

 

Thanks HeftyLefty.

The entire bill, including the $75.00 Diaganostic fee came to $196.24 with tax. I am quite satisfied with the end results. I should qualify that by saying "If it continues to perform as it did last night".

I was going to take it back out today, but Momma wants to do some last minute shopping and the temp is 5+ and still falling and with a 40-45 mph wind right now, I'll hold off for a bit....

Thanks again for your comments..

MERRY CHRISTMAS to you and your loved ones........

BobPo

 

i was hoping this would help mine.. it didn't but read on

i had broken the gas cap before all my troubles, and, well, so, REDNECK PRIDE (that's what's printed inside JB weld tubes) i made up an improved cap..

I took a 3/16 inline fitting, and cut off all the NONWORKING fuel level "crap" from my cap. You see, the clear cover fell off, and i wanted to see if it would run right.

I connected all the "overflow"lines, and replumbed it, from gastank to carb...

fired it...sputter.... sputter... sputter.... @#$%@#$!@ pulled a line off... fired it right up...

WTF, right?

got it warm, reocnnected.. died..
@#$@$
and
@#$@

unconnected, fired it right up...

well, hell...

rerouted the overflow lines to the trailer hitch, and ran it for 15 miles...

it dies ONCE when i locked everything up from top speed to zero...

heck, i was even able to pull start it, which i was NEVER able to do before.

the heck with it, its a great running 98
jeffe

 

Hey Jeff,

First off, MERRY CHRISTMAS TO YOU AND ALL YOUR LOVED ONES...

I can equate with your problems as most of my equipment is old stuff and I am always redneckin' stuff to make it work. But as the old sayin' goes, "If it ain't broke, don't mess with it", and well to counter that I'd say "If it does break, mess with it and you'll come up with sumethin'....and then it might even work better than it did before..

Bobpo