Hey guys new to the forum and I have some questions about my 2001 Xplorer 400.

I purchased this atv used in march of 09 and I am having 1 problem with it that I just cant figure out.

When loaded down or going up a steep hill or when really on the gas it just boggs way down wont rev up and it will backfire through the exhaust once or twice. In neutral it will rev up fine and this thing always starts right up right away. It has a brand new spark plug and a brand new fuel filter. I took the carb off and it looked brand new inside. Anybody have any ideas at what to look for to fix this problem? Also what is the gap supposed to be set at for this particular ATV?


Thanks

 

did you take a look at the plug to see if its running lean/rich? could be the float isnt set right and kinda of running out of gas when going up hill(because of float level). you may want to change the oil in the engine damper if it hasnt been changed or at least check the level. did you make sure to have the air screw set correctly on the carb as well? just a couple of ideas

 

Check buttons in secondary clutch, can cause these symptoms, makes you think its the motor but the secondary clutch is not backshifting properly under load and causes engine to bog.

 

Thanks for the help guys. Hopefully I will have some time to tear into it this week.

 

All right so I have some time to work on it tomorrow what should I look for when checking the buttons on the clutch? I will admit right now I am pretty new when it comes to working on this kind of stuff.

 

he is refering to the buttons(shoes) on the secondary(driven)clutch which the helix runs on. you have to take the clutch off and apart to see them.

 

DITTO on the secondary buttons.Whem you get the clutch apart the buttons should be rounded not flat spotted or gone

 

Sweet thanks guys I am heading out to the garage now to pull the cover. Also have to replace a seal in the front hub. I better get working have a trail ride coming up next friday.

 

Allright I took the clutch apart and the buttons are worn very bad so I will replace them. My only question now is when I put the clutch back together how do I know how much tension to put on the spring? I should have marked it before but its too late for that now.


Thanks guys

 

i believe it is set on 2 on both ends.