I would like to hear from some of you experts out there.

My ATV...2004 Arctic Cat 500 TRV, (2 inline seater) 475 miles, bought new

Here is my dilemma[img]i/expressions/face-icon-small-disgusted.gif[/img]

1. What would be the symptoms of a CDI Unit going bad?

2 What would be the symptoms of a Regulator/Rectifier going bad?

Being from the Old School, these electronics baffle me.

<u>All answers will be greatly appreciated by this old man...</u>

 

No expert by far, but in my experience's with CDI's, they either work or dont. No warnings.

regulators usualy overload or underload, or go out all together.

When you say fails to start. Do you mean it will turn over but not fire? or do nothing at all, no clicks, no lights etc..

 

CatCrazy,

Thanks for the rapid response. This is what is happening;

I can start it just fine anytime of the day, but not late in the afternoon. But even then, sometimes it will start only to stall after about 30-40 seconds. I have cleaned the carb, filters, everything. If I pull it out into the yard and use it around the property, it starts and runs fine.
But again, if I leave it out and then try to start it in the late afternoon or evening, NO GO! Plus, once it starts to stall, I try the throttle sometimes, but that only causes it to pop and sputter a few times, then into the stall it goes.

Another interesting thing to me is that there's no sense in trying to start it later unless it has been pushed back into the shop (my big garage) for a few hours. Usually I just let it go until the next morning, and then it starts fine.

This situation has gotten worse over the last couple of years. Not being familiar with the regular/rectifier doesn't help. You see, I don't really know what it does.

If all it needs is to replace the Reg./Rect. Unit, I'll go ahead and get one. But I don't want to play guessing game if it doesn't need it.

You know, I'm afraid to take it off my property for fear it won't make it back. It weighs over 732#. Not an easy push. My wife and I want to take it out to the Paiute Mtns this coming year so hopefully I can remedy the problem.

Here's another puzzle, I had been riding it for a couple of hours recently in the afternoon, and it was great. Then about 100 yds from the house, it went into one of it's moods and just stalled. I think it sensed that it was getting late.

Hope this can help get to the bottom of this.

Thanx again.

P.S. I love this Cat, it's absolutely great, well, except for this stall problem....

 

I've had a similar problem with a freinds atv and it turned out to be bad gas. I drained and flushed the tank replaced with diff fuel and it ran great. his bike was doing the same thing would start and stall all the time and the warmer the engine got the harder it was to start and the shorter it would run hope this helps

 

The good news...the CDI from 2004 to 2008 and regulator/rectifier from 2000 to 2008 are all the same as long as it has a Suzuki motor.
So, chances of finding used if you choose to are better. Yours does have a Suzuki motor.
That said, I would lean toward fuel myself.
That or something as simple as moisture in the plug boot.
Drain and clean the carb and fuel tank, dump in some "Seafoam", blow out the plug boot and throw in a new plug for good measure.
Also, check for good ground and connections on the battery.
Even a connection that "looks" good can be bad, giving less than optimum voltages.

BTI

 

Check choke for proper operation. Check voltage to choke, and that choke is pulled fully open.

 

Good idea HL I keep forgetting these have electric chokes on them

BTI

 

Say Hefty Lefty and BTI,

That reminds me, I have already replaced the elect choke once at about 250 miles. That was about 1-1/2 yrs ago. I did this because that's what I first thought the problem was. And of course it started right away the next morning. But then, the problem occured off and on again and again. I will definitely check the voltage going in and also if it is functioning properly.

Thanks for the input..BobPo[img]i/expressions/face-icon-small-confused.gif[/img]

 

Trace the choke circuit through the wiring harness, look for chafing of the wire. Also, carry your plug wrench with you when you ride. The next time it stalls,pull the plug, ground it against the engine, crank the bike and check for spark. It should be blue. If NO spark, check CDI &rectifier wiring. If GOOD strong spark, look at fuel delivery system.

Also, if the quad cranks with the KEY ON but KILL switch OFF, check the KILL switch. It could be corroded or have moisture in between the contacts, killing the ignition, even though the key is ON. And, if you have any other safety switches integrated with starting / running the quad, such as foot brake switches that have to be depressed to start, or brake levers that have to be pulled, check them as well.

 

Hey HeftyLefty,

Well I tried the voltmeter on the Elect Choke wire both with it plugged in and after unplugging it. The only read that I seem to get is about 2 volts. Does this seem right or am I checking it improperly? After unplugging it, I checked for voltage from the wire that connects to the Elect. Choke.

Here's another scenario; Any time I start it during the day or in the shop, it always starts and runs fine and I have to leave it run long enough for it to warn up so I can get it into gear. If it is running too fast (not warmed up yet) I can't get it into High (it's an automatic tranny). The only way to get it into gear without letting it warm up completely (2-3 minutes) is to put it into high as quick as I start it. But generally speaking, I let it warm up prior to driving it.

By the way, do you know where I can get the "<u>shop or service manual</u>" for this quad?

Thanks again,

BobPo

I wish you and your family a great Happy Thanksgiving.

It's really nice having someone to talk to who has some knowledge of this machine.