I have a 1997 Sportsman 500. The problem is when I put the quad under load or even past 1/4 throttle it spits and sputters like its starving fuel it will sit there and idel all day like nothing is wrong. I have drained and cleaned the gas tank replacing it with fresh gas, changed the fuel filter. I have also changed the belt. A friend and I checked and cleaned the carb and fuel pump and I also adjusted the valves. I remember it doing this a while ago like it was in reverse without the override pushed in so I would push the button and it was like it would clear itself up. It seemed to do this when I would first started to go out riding now it is all the time. I also checked the ETC. Any suggestions or comments would be very helpfull thanks.

 

Try disconnecting the black wire from the speed limiter box and see if that fixes it. Be careful when you go in reverse like this, because you will get full speed/power in reverse even if you are not holding in the override button.

I have learned that these speed limiter boxes can be problematic and create symptoms very much like what you are seeing. Have you tried running it in "forward" with the override button pushed in? It would be interesting to see what that does, although the real test will be what happens when you pull the black wire (which disables the speed limiter entirely).

If that is the problem, you can either just run it that way (I don't personally recommend that for safety reasons), or you can get a new speed limiter switch for about $65.

 

I forgot to add that I changed the spark plug and checked out the wiring to make sure nothing was shorting out. I have tried pushing the override button while going forward but it doesnt help. I was looking through my Clymer book and cant seem to find the speed limiter box.

 

<div class="FTQUOTE"><begin quote>Originally posted by: perchman

...I was looking through my Clymer book and cant seem to find the speed limiter box.</end quote></div>

It is #41 below:



Notice where the diagram shows it bolted to the frame just down and over from the hole that the high beam headlight plug is coming out of. On my ATV, it is right beside the electrical panel, and the best way to disconnect the black wire is from the electrical box, NOT the reverse speed limiter.

To get at it on my ATV, I have to take off the gas tank cover and then the "hood" that contains the high-beam headlight and covers the radiator. Once that stuff is off, if you are standing in front of the machine facing it, the reverse speed limiter is just to the right of center, almost touching the electrical panel. The black wire on mine is only about 4-5 inches long, and connects from the reverse speed limiter directly to the electrical panel. I just unplugged it from the electrical panel to solve a problem where it would die if I put it in reverse unless I was holding down the override button.

I have a high degree of confidence that this might solve your problem... my fingers are crossed... good luck!

 

I will have to check for that tomorrow its to cold to do it tonight -23 C and I am out of wood for the stove.

 

Does anyone think it could be the cam ?

 

Yes, it could be the cam.

If it is the cam, you are obviously looking at more money , more skill, AND more work... possibly a trip to the shop unless you are pretty handy with a set of tools.

I hope not the cam, since that will be a lot more difficult to fix than the reverse speed limiter. Did you try the reverse speed limiter yet? If so, how did that go?

 

No I didnt get around to doing anything tonight. I work outside and had just about enough of the - 20 C weather for the day.

 

<div class="FTQUOTE"><begin quote>Originally posted by: perchman

No I didnt get around to doing anything tonight. I work outside and had just about enough of the - 20 C weather for the day.</end quote></div>

Dude... it SUCKS to be you right now.

 

Well I finally got around to disconnecting the speed limiter and it still does the same thing. I am going to take the carb off again and clean it one more time. If that isnt the problem I think I might as well do the cam.