Issue I cant solve
Im hoping to borrow some of the knowledge that is floating around here. I have an 04 500 Predator. I was in Oregon at the dunes last week. She ran like a bat out of hell on the first day. Towards the end of the day it started getting some backfiring. I found the ideler screw fell out of the carb (and somehow managed to wedge itself under the starter! So I still had it when I got back to camp). On the second day I went out turned it on to warm up while I was putting on riding gear. It started right up and purred like a kitten for about 2 minutes then all of the sudden shut off. I went to restart it to take off but it just turns over and over but wont fire. While at camp I pulled the carb and cleaned it although it was already clean, replaced the fuel though it was new, checked my plug, it was light brown and blue spark but i still put a new plug in anyway, air filter was just cleaned, oil had just been replaced and was full, battery tests great and is always on a trickle, checked all connections, and tried pull starting it several times throughout the whole process only to have the wheels lock up each time the clutch was dumped. So we packed up camp and drove back to WA so I could get it in my shop out of the elements and open it up.
At home I retested the battery (yes, under load) and its perfect. I pulled the starter and disassembled it. The brushes seem fine to me. They are about 1/2" long id say and had just a little slag built up on one side of each. The armature looked fine, plenty of copper elevation still, just coated in a real thin layer of powder. I wiped that all down and put it back together. Next I opened the starter cover to expose the fly wheel. No metal shaving in there (except tiny little flake/specs in oil, normal wear?). All of the teeth on the exposed gears look perfect as well. The visible portions of the fly wheel don't show any cracks, dents, or dings. I can put a 3/4" socket on the nut and roll the motor no problem. My next step would be to pull the fly wheel so i can get to the bendix. But I don't want to do to if I don't have to. If the one way was toast wouldn't I expect to see larger shavings, or chunks when I opened the cover?
Sorry if that is long winded. I'm getting to that point of not knowing what else to try. I thought about the cdi being bad to. But I have good consistent spark. And the starter seems to be spinning fine. So that kind of leads me to believe that is not the problem. But I am open to any and all suggestions.
If it helps, here are mods that might be pertinent to this issue; K&N cone style, Voertex CDI, obviously rejetted, FMF exhaust
Mods in general; custom +4.5 swing, 13/40 gears, nerfs, front and rear bumpers (front removed for dunes) 22" tires (full set for trail and for sand) vinyl wrap...yes i did it myself for $150, skid plate (also removed for dunes), steering, gas cap, fresh wheel bearings, custom oil tank