So, I was having an issue with my 96 Sportsman 500 bogging down when given gas. It was backfiring horribly and just would not go anywhere.
I replaced the carburetor with a new Mikuni carb, put everything back and now it will not start.
It turns over but will not fire, I replaced the fuel filter and gas is flowing, and I checked for spark and that is good.

Not sure what to try next, anyone have an idea to try?
Thanks for readying and any advice is appreciated.
Terry

 

Probably wasn't necessary to replace the carb as you could rebuild it if it wasn't physically damaged. This model falls in line with a group of models that had cam heat treatment problems.The exhaust lobe would wear down and usually they would idle ok,but spit and sputter when throttle was applied. Pull the cam over and inspect the cam lobe. If it's ok,check valve clearance. .005 intake and exhaust. Here's an example of a worn exhaust lobe versus a new cam. If the cam and clearance is ok,pull the black wire on the terminal boad that goes to the reverse limiter. They can short out and cause problems also. Item#31 in the parts break down. Plus air box and filter have to be installed and sealed properly or it will not run right also.

 

Hmmm, I guess I should just sell it for parts. I was hoping for an easier fix, I'm not sure I have the time or knowledge to inspect/replace the cam.
I paid $600 for it back in 2002 and have never had an issue with it really.

Thanks.

 

Also, would the cam keep it from starting? It would start fine and idle fine like you said, but now after replacing the carb, it will not start.
Just turns over and over but no fire.

Thank you again

 

Lay the spark plug against the cylinder to verify if you have spark or not. You can even pull the plug cap and see if you have spark from the bare wire.Pull the black wire from the reverse limiter also. If you still don't have spark,pull the black kill wire from the cdi module and check for spark. This isolates the cdi from the switches. Still no spark,then that could be stator or pick up coil related. Ohms resistance between the white and white/red pick up coil wires should be around 97 ohms. Couple different colors on the stator wires to cdi. IF you have Black/red to green,446 ohms between them. IF you have Black/red to red 450 ohms.

 

OPT, from reading many of your prior posts, I thought the valve clearance was .006", not .005".

 

Yep,you caught me... Guess I was thinking about Ktm clearances or it was getting close for my mid morning nap that old retired folks need..

 

I just figured you hit the key next to the right one. I do that a lot with letters, especially since a few have worn off. But I can't blame it all on the keyboard.