All posts by dstech

Uncategorized

2004 Sportsman 500 front hub capacity?

Even though I’ve posted a couple of previous questions, I’m still a newbie.
My wife’s early 2004 (new to her last summer) is not engaging the left front hub lately. I drained the fluid from both, pulled the caps and cleaned the inside as instructed. Fluid was really dark. I could only get about 1oz in each side before it began running out the fill hole when rotated to about 3:30. Shouldn’t they take 4 or 5 oz each? Any ideas?

Also, every time I try to search a topic my results come back with nothing found comment. What might I be doing wrong?

Uncategorized

2003 660 carb tuning?

I bought another 2003 660 with 1,500 miles $3K for my dad and sold his old one that was needing some work with 3800 miles. The good news is I was able to break even on the deal and the low mileage one rides much nicer and and is "tighter" as it was never used to plow. All in all, a much nicer machine.

I have spent hours/days researching and reading carb tuning threads from all over the internet for this machine. I spent all afternoon Saturday trying to get the fuel screw adjusted to smooth throttle operation and I just can’t get it right. My Dad lives 3 1/2 hours away so I don’t have immediate access to the machine.

Before swapping out the machines, I did a bunch of maintenance and cleaned the carb as the lower mileage 660 was leaking gas on my driveway out of the carb overflow. The previous owner ran the carb dry every time he put it in the garage so the o-rings were all dried out and crusty. I put a Moose carb kit in it (the same one I put in his previous griz and it ran like crazy) and now I’m having a very hard time getting rid of a stumble in the low throttle range. Seems to be right where it is transitioning from the pilot jet circuit to the needle jet circuit. He is using it to plow and ride for fun. It stumbles at 4-6 mph in low and 7-10 mph in high range but runs like a raped ape as you continue to push the throttle! This issue makes it very difficult to plow with as this is the main operating range.

When I took out the fuel screw, it was set at 3 3/4 turns (which seemed to me like a very rich mix for 900 feet of elevation). If I remember correctly, tuning the fuel screw should start at 2 1/2 turns and adjust from there correct? It ran strong with no hesitation when I picked it up. He had the carb serviced a long time ago and it was done at a dealer so I assume that was how it was set from the dealer service.

Anyway, I cleaned the carb thoroughly and installed the new kit. As many of you know, adjusting the fuel screw on a 660 is a real PITA without taking the carb off or at least loosening and rotating it. I made a short screw driver out of a nail and a short piece of dowel to make adjustments without tearing things apart. I have adjusted from 2 turns out all the way to 4 turns out in 1/4 turn increments and I cannot get rid of the stumble. At 2 1/2 turns out, it barely stays running as I apply the throttle until it hits the needle jet circuit. At that point, it runs and accelerates great. When I got to around 3 1/2 turns out, it was better but still not a clean transition to the needle jet throttle range. The diaphragm appeared to be in good shape as well as the intake boots between the air box and the engine so I don’t think I have any issues there.

Anyone have any tips I can use next time I get down to his house to work on it? I’m guessing I will need to re-clean and start from scratch? I also forgot to check to see if the reverse/override limiter (does it have one?) was bypassed or not. Could that have anything to do with it?

Thanks in advance for any tips or help on this! I need some ideas for my next trip down to work on it.

Uncategorized

07 700 Griz, missing, stalling, weird speedo issue?

Hi everyone, new here, have been reading the forum for years as a non member and have put to use a ton of info found looking through the threads. Have been riding some sort of Yamaha since my first new warrior in 89, had a Raptor,450 Griz, and now a 700 Griz.

I have a problem with my 07 700 that has me pulling my hair out. Bought the 700 new in 07, currently has 230 hours, 1290 miles. Mostly stock, except K&N, and clutch mod, the pod mod to add fuel, wheels and some 26" tires.

3 years ago while doing some trail riding it developed a low speed miss, wouldn’t idle, would backfire occasionally but ran well in mid to upper RPM. I thought I had gotten bad gas, or something had gotten wet because it went away the next day. Then from time to time it would occur again but go away. Well about 3 weeks ago, my son was on it and it quit completely, would crank fine, but no start. Checked for spark, had really poor, pale orange, intermittent spark. Changed plug (old plug looked great), still no start, changed coil, fired right up…thought problem was solved. However it still had a miss and surge while riding. Rode for about 10 minutes and it quit and wouldn’t start back. No codes found in diagnostic. Found the wires coming out of the stator had rubbed against the motor mount, rubbing bare and grounding out 4 of the 5 wires. After un-grounding it fired right up. I cut and re-soldered the 4 wires, heat shrink, and black plastic cover protected them.

Rode for about an hour, ran perfect, no misses, stumbles, back fires….perfect. Then all of a sudden, the issue was back, it quit again, but this time it would start back, but had a terrible miss, and backfiring…..plug looks black and damp, strong smell of gas. Weird thing is, sitting still and reving the engine up in park, the speedo will jump around from 0 to about 20 mph (its not in tach mode)??? Still no codes, checked the TPS in diag, says 16 with the throttle closed, 101 wide open.

Does anyone have any ideas?? Hate to take it to the dealer when I can change parts as easily as they can. Speed sensor? ECU? CDI?

Thanks in advance for any help!

Uncategorized

2009 Sportsman 500 H.O. Fuel Pump

Hi All: Getting back as Im still having a fuel issue with this bike and not sure if its pump, carb. or what. I bought an "aftermarket" pump and carb. and the bike will not start after sitting for awhile. And im not sure why but if I blow into the tank either by mouth or air nozzle itll fire up. as it warms up i start to see fuel coming out of the rubber hose at bottom of bowl. As I rev it up more fuel comes out. It eventually will stall out and more than likely have to pressurize tank again to get it to start. Any thoughts or troubleshooting techniques would be greatly appreaciated.