First of all, this TB was in sad shape. I have ripped the whole thing apart(except the engine) and put it back together more than once. When I got it, it did not run, go it gear, or more. But, it was free. With some welding, grinding and patience, it ran.

Last fall I parked it and tore it apart for a few things. I put in a starter (for the first time) and a battery. I reassembled, and now, cannot get it to start. I dumped the fuel, took apart the carb (which I know little about), blew air through various passages in the carb, and reassembled.

It almost starts. I threw in a new plug for good measure. It gets spark, but even with ether, will not fire (more than one to three turnovers). I have adjusted the carb screws, but do not know of a good base setting.

I could check compression... what should it be on these things?

Thanks for the help. I appreciate it. I really wanna get out riding again and I can hardly afford gas (e.g. parts/new atv not possible).

 

I am having the exact same problem with my '96 right now. It is so close to starting, but just won't fire. I've tried everything. Good luck. If I find anything out I'll let you know!

 

i had the same problem with my 96 TB.
try pulling the cord a coupple time with the key turned off
then try to start it first with out the choke then with the choke on

 

compression should be at least 125 psi and up. air screw good starting place would be a 1 1/2 turns.

 

after it almost starts pull the plug, see if it is wet or dry. Wet too much gas dry not enough. You could try to splash a little gas into the carb and try to start if it fires up and dies its not getting enough fuel. Go to partsland.com they have good micro fische breakdowns of the carb and other parts, maybee something was put back together wrong. Or something needs better cleaning.

 

Was it stored inside or outside?

 

It was stored inside. Thanks for the tip about 1 1/2 turns. That is about where I have it. For the other screw, it is about 4 turns out. The thing is REAL close to starting, but just won't catch.

I HAVE A THOUGHT. I do not know how the over-ride switch is supposed to function, but on mine, if you go into reverse without holding it in, it behaves exactly the same as this starting problem (stutter, stutter, stutter). I was working on the gearcase, and the connecting rod, and the shifting arm, so this seems highly likely that it might be out of position somehow. How can I bypass this to test it out? What wires connect it? Does anyone have a wiring diagram?

I have cranked this new starter so many times! It seems to do best if: 1) crank for a little bit with no choke or extra gas. Like you are making certain the carb bowl is full. 2. Open the choke, and crank a few times so it starts to fire and warms up the engine with a few explosions. 3. Close the choke, and turn a few more times. 4. Open the chooke most of the way -- this is the point where it is closest to starting!

 

By the way, for parts diagrams, I have found http://parts.polarisind.com/Browse/Browse.asp to be VERY helpful, for it also gives you original and current part numbers (helpful for finding aftermarket parts much cheaper). But no one seems to have electrical diagrams. PLEASE, does anyone have this?

 

spray fuel continuously down the air intake while starting it or running it to see if it'l stay running to see if its a fuel delivery problem. spray dont pour. spray bottle.

 

I'll say you need a top end job. Check the compression before you waste anymore time. Doc