Yeah, that could kinda change the whole outlook.

 

Also, dry rotted carb? Boots as well? That could be your issue there. Crack in the boot is letting too much air in. But that would also change the spark plug color if you did a chop test.

 

I apparently thought I was 20 again… It did start doing this shortly after It was upside down… I think the whole intermittent thing has got me all turned around… Or… upside down…

 

ALSO, is your temp gauge working properly?

Does your fan kick on while you're riding? (Try starting it and revving it in your driveway a few times, let it idle a bit, revv it not hard tho, ...and see if your fan kicks on)

I've replaced three fans on the 05 500 and 08 400 once.

 

Agreed!!

 

Yes, the fan does cycle as advertised, the Temperature gage is working properly, I’ve had the plastic off and on, on this machine so many times I’m thinking of putting Velcro on it.

I’ve chased down bad electrical connections cleaned/degreased and gooped with dielectric grease

I’ve changed and re gapped the plug

Cleaned carb.

Checked and serviced battery

Timing is good….

I know I’m missing something simple, I think I’m going to swap out that air breather boot, just seemed too simple..

 

VELCRO!!!

I'm awaiting new plastic to be delivered today for the 05 500 .... If they can't keep it between the ditches and part way on the trail, I'm gonna make them start replacing parts and doing the maintenance work themselves!!


You can get the carb boot and breather boot for under $25 on Ebay. Honestly, tho... I'm with Scooter on this. I'd replace that boot and see how it goes.

 

With it running, spray some carb cleaner on the boot and see if the rpm's go up.

Don't over spray it though.

 

Cool guys, I will do that tonight... Got that stupi Job thing today... Gets in the way of a lot of things. I'll keep you posted. Thanks again!

 

No prob, keep us posted!!