This 2006 machine has approx 10-15 hours on it. I've noticed that the charging system is overcharging the battery - (Battery acid on top of battery and running down back of engine). This leads me to believe that my voltage regulator has gone bad. Does that sound right?

When this atv is run, it starts right up, will run just perfect for the first 5 - 10 minutes, then starts to die. At this point it can be restarted. After a few more minutes of running, it will die and cannot be restarted (Cranks and cranks, but does not fire) until it has cooled for at least an hour or more. Then the same thing will happen. I have checked the fuel supply - by draining the float bowl - that works fine. The battery is always disconnected when not in use and is recent. Would the voltage regulator cause this?

Could the voltage regulator ruin the brake light switch in the brake lever? That has gone bad as well. In order to start the atv, I have to jump the 2 wires that are supposed to connect to the brake lever. With them connected to the lever, the brake light will not light and the starter will not engage.

 

I'm not big on electrics but IMO, the charging problem needs to be addressed as it could be causing the CDI to heat up and fail.

 

Do some of the imports have a CDI/rectifier all in one? that, as LT80 stated, could cause a major problem, once electronics get to a certain temp, the resistance builds up,and they stop conducting until the temp drops,allowing you to start again. I had an old snowmobile like that, start and idle great cold, run it down the field about 5-10 min, it would lose power and die and not restart, cool off, and run great. I sold it, the buyer replaced a coil, and it ran like new.

 

UPDATE! I replaced the Voltage Regulator with a new one and that took care of everything! I took the kids out riding on Saturday and the Sunl ran the whole time without stalling once! Having no issues for a few hours of run time was great! Everyone had a blast! No more battery cooking either!

 

In my elation at a well-running machine, I neglected to address the jumped brake wires. I simply left them together (Both inside one insulation boot to maintain contact). I'm not sure if it will work when attached to the brake again, or if the brake switch was fried from over-voltage. I will attempt to re-attach it this weekend and see if I need to order a new assembly.

The only thing that the wires & switch do is prevent the engine from starting without first holding the brake (And it operates the brake light). Being that I am the one that starts the quad for my kids, it really isn't a huge issue...but it does bug me & I'll have to fix it if it has permanently failed.