’96 Kingquad Running Rough
I just bought a 1996 Suzuki Kingquad 4x4 300 and it runs real good until you start on a pull then it acts like its running out of power, it wont hardly go up the smallest hills? I need help???
Dennis Mills

This machine could very well be running out of power, my friend. The facts are kind of stacked against you at the moment. Being a 1996 and also a used ATV the possibilities are endless. I would first check compression on the little 300 ticker. Low compression on any engine will rear its ugly head when put under a load. Try a compression test first and maybe even have a leak-down test done to determine if the piston rings are holding up.

No Rev
I have a 2001 Arctic Cat 500 auto ATV. It will start and run fine. But will not rev up just bogs down and back fires. I have cleaned the carburetor, installed new needle valve, adjusted the float, new diaphragm, changed the plug, put in fresh gas nothing has helped. What am I missing?
Thanks,
Jimbo

The fact that you did go into the carburetor tells me you have a good idea, but I think maybe you didn’t go far enough. The needle valve replacement was a good start, and I rarely have to replace the diaphragm but I would recommend pulling the main, primary and any other jets this carb has for a good cleaning. Now don’t let the shiny exterior of a brass jet get you all excited and think it’s clean just from the looks. Primary jets have really small holes in them and they clog easily with varnish from bad gas. Check that out and get back to us.

What Gear?
I have a 2001 Rancher ES 4 Wheeler. The Display is not showing what Gear Position that you are in and the Speedometer is not working also, Could it be in the Display or in both of the sensors? Any ideas?
Please email me if you might have the fix.
Thanks!
Sammy

It is possible that both of these sensors are having trouble; however, if they both went out at the same time there may be a short in the wiring for them. Look over the wiring for the Rancher for any chaffing or cuts. There is a possibility that the plugs attached to the sensors simply were pulled loose. Look around a bit and you’ll probably find the problem for one actually is affecting both.

Big Bear Dying
I have a big bear 400, 2001. It starts fine then runs good until warmed up. But then dies out when idling and sputters at mid to high rpms.
Any help would be great.
John W

Fuel, spark and air are the three components that make your ATV run, and if any of these three get obstructed in any way there will always be trouble. This sounds like a fueling issue to me. There are several other items to check but I would start there. If the carb is good and clean – and I mean really clean – inside the jets also then look at the plug. How old is your plug? Is it fuel or carbon fouled to the point of not running? Also, some coils will give trouble when warmed up to riding temps. You’ve got work to do my friend! Get a service manual from your local dealer and dig in!

Hole in Motor
I got a ‘02 Suzuki lt250 and it blew a hole in the bottom part of the motor. And will turn over and everything but wont start. Can anybody tell me if I would have to buy a whole new motor or is there someway to fix that?
Devin

Devin, I’m sorry to say that once you start blowing engine parts out of its case you need to start looking for a good repair shop and possibly a new engine. The four banger has had its fill, and I’m sure you’ll be better off with something new. Send us some pics so we can store them in our “don’t let this happen” files!

Yamaha Clutch Replacement
I bought a GYT-5LP56-30 clutch kit for my raptor. As I can note each of the friction plates have (six of them and have a green mark) two notches. Other two plates do not have the notches (these two have a blue mark). Are these markings for a particular orientation when installing?
Please advice.
Thanks,
Juan

I cannot stress enough the importance of a factory service manual. The GYTR clutch kit should have had defined instructions in the package, but if not I always turn to the factory service manual. How cheap are these? Well, not real cheap in paperback form, but I have found that when I need it really bad, price isn’t a factor as I would pay any amount to know what I’m doing. Call your local Yamaha dealer for Yamaha branded installation instructions and order a service manual while you have them on the phone!

First Timer
I am new to the world of ATVs and I have been referred to Polaris for my first purchase. As your comment states you are a primary trail rider but like to ride in sand, would you pretty much say then the Outlaw 525 IRS would handle just fine on beaches/sand dunes? I want to be able to ride this ATV both in woods/dirt trails as well as on beach/sand dune areas. Thanks for your advice in advance!
Fidel
 
Every ATV is different in all terrains. Some handle better in the woods and some in the dessert. I would say that every ATV can be set up to your needs in any condition, but first you’ll have to find one that fits your riding style as well as your comfort level. I wouldn’t pick an ATV because someone says its good in the sand or trails, I would rather ride several and get one that I feel comfortable on in the sand or trails because in the end you have to fit the atv before it will fit you. Got it?

Front Wheels Out?
I have a 1993 Polaris 350 4x4 and the front wheels have quit pulling. The 4x4 light still comes on but that's all. The right wheel will pull sometimes but not often. I know nothing about how they activate or what makes them work but I know I can't afford to take it to a shop right now. I bought this bike new and it has never given me any problems like this, if fact hardly any problems. Can you give me some steps to find the problem?
Thanks,
Randy

The front end on this ‘93 350 has several factors that can be causing the front wheel to not turn. The first is the magnetic coils that actually help engage the front drive on each wheel. The next is the chain-driven front drive assembly. The cold hard truth is that you’ll have to tear into both of them to find the real culprit. The coils are Polaris part number 4170003 and these are not expensive at around $30 each. Start there and let us know how it works out.

Running Hot?
I have 1996 Suzuki 4x4 ATV and it runs fine when cold but after 20min it shuts off when I try to restart it runs on half cylinder or seem like.
lonegone

Sounds like the Keniffle pin broke and jammed up into the Jackson rod. When this happens it takes out the muffler bearings. Id look into the coils first, though.

Same Problem
Dennis Mills has the same thing wrong with his 4x4 that I have with mine 1996 Suzuki 4x4 quad 300 listed Aug 18 2010
 Dennis Price

“See response to Dennis Mills Problem”

Knock Knock
I have a warrior 350, '02 model that's bored .40 over. Just put a Weisco piston in it and it knocks when spinning the motor over. Compression, oil and fire are good. What could make the knocking noise?
Luck

Sounds to me like you may have forgotten something inside. Did the timing chain tensioner get put back correctly? How about the chain guides for the tensioner. I’d do a quick look see inside the engine before spinning that fighter over and over so you can hear the knocking! Get a service manual; I think you’ll love it!

4x4 Slip
My 2000 Yamaha Kodiak will slip in and out of 4x4 on its own. When climbing a steep grade it’s in perfectly but when on the flat ground it jumps out on its own. What’s the problem?
Thanks,
Clyde

These front differentials are engaged by a servo motor mounted on the side of the differential. It is possible that you are having trouble there. It’s hard to decipher your problem with out more information, but look into the electronics around the servo pack and you might find your answer. It could be as easy as a shorted wire.

Fuel Flow Issue
I have a 2006 Suzuki z400 quad and fuel flows out of the overflow tube on the bottom of the fuel bowl when the bike is running or not just at a faster pace when running whats my problem?
Justin Byrd

Justin, this fuel tube is indeed an overflow fail safe. This means that too much fuel is getting into the carb. The only way in for fuel is through the needle valve, which is attached to the floats. Check to be sure the needle valve is closing all the way and be sure the needle valve tip, which is rubber, hasn’t gotten corroded away enough to allow fuel past the needle jet. Sometimes its best to just replace these parts rather than struggle to clean them.

Cylinder Noise
I have a 2003 Polaris 600 Sportsman that will run fine for awhile and then start running on the left cylinder with a metallic mechanical noise on the right. If I rev it up it will finally clear and run for a while before starting the one cylinder thing again. It actually quit for a long time after I changed a leaking needle and seat and then started again. Could it be a faulty lifter leaking down or what?
Ron

If it’s making a metallic knocking noise it’s a little deeper than just a leak down by the valves. For starters, I would check the oil by just draining it all out over a couple white paper towels. Be sure nothing is grinding away at the engine or its parts inside. This could be related to several things and some of them being timing, cheap gas and/or timing chain tensioner. Start with the oil and go from there.

Carb Replace?
My son has a mini 110. On the bottom of the carburetor there is a small hose looks like an over flow hose. But it continues to leak fuel. I tightened the screw but it continues to leak. Do I need to replace the carburetor?
Dan

I’d check into the carb a bit before replacing it. I’m sure this is a problem with the needle and seat in the bottom of the carb. That’s how fuel gets in and when clogged the fuel will continually run out the over flow. Start there, my friend.

Carb Question
Rick-- A carb question. I have Yamaha Warrior with a Mikuni BTM36 (single cable) carb. I have replaced all parts from a carb kit and cleaned the whole thing about 10 times. But when it gets warm, I hold at 1/2 throttle, it stumbles. When I turn the peacock valve to off, the stumbling goes away (the engine stops afterwards). So the stumbling is from too much fuel. I replaced main jet with a smaller jet--it still happens. Set the needle to a leaner setting (1 up), still happens. I have set the float level--no change. Run with no air filter--no change. I have tried other stuff too--no change. There is a plastic piece that the needle jet goes into, it is attached to the carb. Could it be desolving due to the ethanol in fuel and making the jet act to rich? Anything at all? I am going nuts on this? Thanks.
Jim Cole

There are only a few ways that you could be running rich and it seems you have covered most. Have you had any trouble with the choke at all? Sometimes these choke mechanisms can get corroded and stick. Even if it’s halfway in or out it could create that trouble. Check it out.

New Park
How do you post new ATV Parks on here. There is a new one in Pineville La. ,That is really good. It’s right off of Shreveport H.W. It’s only been open for about 2 weeks now. Weekends only and its really nice to have a car wash right in front of it, along with a laundry matt, to wash your clothes. After they get muddy. We had a blast and really enjoyed it. We will be back there. We went down from Okla. and were very pleased. I would like to share the fun with the others. Just not sure how to post it. Thanks, for helping.
Vonda

Well, here’s a start for our ATV readers. I would suggest also sending a letter to the editor, Josh, at editor@off-road.com.

Clean Float
What is problem when gas run out hose on bottom of carburetor of 660 grizzly?
Patrick England

The float is stuck because the carb is clogged up. Clean that puppy out!

Popping Sound
I have a 2007 Polaris 500 Ho. When I turn there is a pooping sound coming from the rear end. Do you know what this could be?
Tina

Sounds to me like there are some bearings locking up in the rear of your ATV. Get that mule up onto some jack stands and inspect the rear axles and differential. If you’re not sure how to do this then buy a factory service manual to help you. If any of the CV joints are torn you can almost bet that is where the trouble is.

Re: Guide to 2-Stroke Rebuild
I can’t tell you how much I appreciate this article. Because of this article I was able to replace my buddies piston and rings in his Suzuki lt250 quad racer and in return he paid me by giving me another quad racer that needed the same work and he bought the piston and rings so pretty much by reading this article and taking a couple hours of my time I was able to own a race ready fast ass quad. Thank you for posting this article cause if it wasn’t for this I would still be trying to save up the money to buy a quad.
Cody

Well you’re very welcome, Cody. Anytime we can help you just give us a shout!!

Shock & Springs
I have 2 stock 2008 sportsman 500 efi looking for better shocks or over load springs I use a sprayer on the back of mine and it squats 3 or4 inches makes steering hard don’t ride hard or do jumps slow rock craw
Robert Barger

I’d say Progressive suspension would have the heavier springs you desire. I would try stiffening the stock ones first by turning the adjusters on the bottom of the shock. This is going to be a trade off though when it comes time to trail ride.

Thanks for all the great questions. It’s almost winter here in the south, and I’m looking forward to some cool riding days up in the mountains! Got Questions? Keep’em coming!
RS

Check out previous Answerman Q&As:
September 2010

August 2010

July 2010