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Discussion Starter #1
Hi there, I have a 2011 sportsman 500 with odd symptoms, I’ve had this atv since around 2014 and it’s ran fine up until about a year ago, ever since then I’ve been battling with an issue with it, and riding yesterday gave me the most clue and problems so far, my atv intermittently bogs and cuts out at 3/4 - wot around 45-55 mph but sometimes runs perfectly normal, yesterday if I held the throttle wide open for long enough “maybe 30 seconds to a minute” the atv would hold roughly 6300-6700 which has been the normal rpms for this wheeler depending on hills and what not, now while at peak rpm out of nowhere It’d drop to about 5600- for a few seconds then jump back up to 6300+ all while I’m never letting off the throttle, and as I keep on the throttle it will do as I said above a few more times then all the sudden the engine will completely lose power as if I hit the kill switch or key, then kick back in and out again a few times then it’ll just die, and after all that mess it seems to take a few seconds longer to start but it’ll start and run fine for a while, if I let off the throttle and get back on it while this is going on, it just pops and sputters, I’ve tried messing with my kill switch and reverse safety switch while it does this and nothing has fixed it, I’ve replaced every fuel / air related thing cleaned the carb, and put a new spark plug in it, another thing i noticed yesterday was 2 times I went through puddles “maybe quarter wheel height” pretty fast it sounded like my exhaust got louder for a few seconds up front then went away, it’s not loud any other time, and I don’t feel air leaking around the exhaust gasket when it’s running so I’m un sure about any of that, Im wondering if a cdi box or a coil could do create these problems, maybe the coil is getting to hot on high rpms and cutting spark?? Another note is the gauge cluster stays on during all of this , Please try to help me out with suggestions, if I find the solution it will be posted!!! Thanks!
 

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Discussion Starter #3
I did check the slide and diaphragm when I had the carb apart and didn’t see anything suspicious, I’ve had other people say it’s the slide or something carb related as there guess, my air box snorkel is clear and I bought a new piece of foam that holds that away from the gas tank plastics, the only thing that would make me believe it’s a carb issue is I get popping when it does this if I let off the throttle and try to accelerate again, and when the power kick out and back in, it don’t back fire like If fuel was loading up in the cylinder, just sharp popping sounds, my friends behind me said it sounded like plastics snapping. maybe lean popping? Not enough fuel for combustion so when it Ignites it just pops?
 

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Sounds like an ignition issue - try closing up the spark plug gap or a new spark plug - if no change try a new spark plug cap - if that doesn't help, then it might be a coil, stator or CDI box (usually in that order) - maybe just run it till it quits completely - that makes finding the culprit much easier
 

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Discussion Starter #5
I kinda agree it’s electrical because of how hit or miss the problem is, I just checked my pulser coil from the cdi wires white and white with red tracer, I’m getting around about 190 ohms is that a normal reading?
 

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Discussion Starter #6
My ignition coil is reading .8 ohms, Im thinking about getting an in-line spark checker and taking it for a ride and see if I lose spark when the problem happens, is it a good idea to run it with wot for a while with a spark checker Inline or could that burn some electronics up??
 

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Discussion Starter #7
I’ve also heard that isolating the black wire to cdi eliminates all kill switches and safety switches Is that true? I unplugged my black wire but haven’t tried it yet
 

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Discussion Starter #8
I took the cdi voltage regulator and the ignition coil off tonight, I pulled the spark cap off and put it back on the wire, as well as the wire at the coil itself, I’m going to clean all plugs and connections there and put it back together tomorrow but before I do does anyone have any suggestions on what to test?
 

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I took the cdi voltage regulator and the ignition coil off tonight, I pulled the spark cap off and put it back on the wire, as well as the wire at the coil itself, I’m going to clean all plugs and connections there and put it back together tomorrow but before I do does anyone have any suggestions on what to test?
Do you have any fixes or results to report? Having similar issues..did you try pulling the black wire to take out the safety features?
 

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I had the same problem on a sled (yes I know this is not a sled forum) and it only happened at full throttle high rpm's. the top rpm would drop off. it got to the point that it started to affect the head light etc. it was the Stator. took it out and it was fried. talked to the dealer and they said prolonged high speed (engine speed) can cause it.
 

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I had the same problem on a sled (yes I know this is not a sled forum) and it only happened at full throttle high rpm's. the top rpm would drop off. it got to the point that it started to affect the head light etc. it was the Stator. took it out and it was fried. talked to the dealer and they said prolonged high speed (engine speed) can cause it.
Is there anyway i can check the stator without pulling anything? The quad has 1100 miles on it with 115 hours. Im hope during that time the bike was full out but you never know
 
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