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Discussion Starter #1
Good morning, this is going to be long winded sorry but here is my issue I bought an 03 sport 400 from my brother in law cuz he blew the motor up and then he tried to jump start it with a large commercial truck battery he heard a click then saw a puff of smoke come out of the engine start/override/headlight switch then nothing at all, I have a 94 sportsman 400 4×4 with a good motor but bike is rough so I decided to switch out the motors as well as the alternator/charging system so the wires would still be the same on so basically it's now an identical motor to the blown one, everything went great hooked up rad hoses, carb etc but I didn't put air filter and box or clutch back on yet because I wanted t make sure it started first I put a new battery in it so I turned key on hit switch and nothing hence the puff of smoke so I jumped the new solenoid I just put on and it cranked over and eventually fired up but I had to keep throttling it to keep it running but barely running and it backfired super loud out of the exhaust I ordered a new start switch for it, does anyone have any idea what might be causing this? Electrical possibly or fuel related? I am stumped any help would be greatly appreciated thank you
 

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19’ 850SP Camo. MtAiry Maryland
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Hmm...ignition control module different from the original engine to the replacement?
 

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The ignitions and crankshafts are different - you need the 94 ignition and wiring harness on to 03 - because the crankshafts are different, you cannot put the 03 ignition and flywheel on the 94 engine.
 

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Discussion Starter #7
The ignitions and crankshafts are different - you need the 94 ignition and wiring harness on to 03 - because the crankshafts are different, you cannot put the 03 ignition and flywheel on the 94 engine.
Ahhh that makes alot of sense I'll start checking into that that may be more than I can do and I certainly appreciate your help Mr.Ed and latebird couldn't have figured it out with out you
 

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I’m totally amazed at latebirds exact fix info
That’s because Latebird isn’t really a person. He’s IBM’s latest supercomputer artificial intelligence experimental computer being field tested on this forum. And it hates the competition..... just ask it about smart phones....
 

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Discussion Starter #10
Well after much research there's been a new twist to this and yes its all my fault I was misinformed about the year of one of the bikes the one that's getting the motor installed is a 97 sport not an 02 so if I put the original 200 amp stator and flywheel back on it can I upgrade the cdi box on the sport to accommodate that? I would have to figure which wore goes where as there are more and different colored wires on the stator than what originally hooked up to bike
 

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That’s because Latebird isn’t really a person. He’s IBM’s latest supercomputer artificial intelligence experimental computer being field tested on this forum. And it hates the competition..... just ask it about smart phones....
I do have a degree in electronics and learned computer programming in the days of Fortran and Cobol - a decade before DOS. I'm just an old fart with 50 years of experience, but not smart enough to fully grasp EFI - give me a good ole carb and I am happy.

Smart phones are the Devil's tool - I use a flip phone, text by computer, only have 4 friends on my facebook page and one of them is not a person, but an entity and I control the entity (entity is another facebook member that is not a person, but a motorcycle club).
 

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Well after much research there's been a new twist to this and yes its all my fault I was misinformed about the year of one of the bikes the one that's getting the motor installed is a 97 sport not an 02 so if I put the original 200 amp stator and flywheel back on it can I upgrade the cdi box on the sport to accommodate that? I would have to figure which wore goes where as there are more and different colored wires on the stator than what originally hooked up to bike
Refresh me - you have a what year & model donor and a what year & model patient?
 

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19’ 850SP Camo. MtAiry Maryland
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Latebird, you crack me up! You must also be familiar with how when i started out, a tune up also involved dressing and gapping the points.
 

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When electronic ignition became the norm, I referred to doing a tune up as "installing the tune-up spark plugs"

As far as points? I still have flex stones and a dwell meter.
 

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19’ 850SP Camo. MtAiry Maryland
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Wow.....I still have the dressing files but dwell meter vanished
 

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I do have a degree in electronics and learned computer programming in the days of Fortran and Cobol - a decade before DOS. I'm just an old fart with 50 years of experience, but not smart enough to fully grasp EFI - give me a good ole carb and I am happy.

Smart phones are the Devil's tool - I use a flip phone, text by computer, only have 4 friends on my facebook page and one of them is not a person, but an entity and I control the entity (entity is another facebook member that is not a person, but a motorcycle club).
See.... would a human say that about smart phones.... think about it... total recall of all manner of parts compatibility.... complete database of all service manuals..... it’s a machine I tell you.... they’ve just cleverly figured out a way to make it sound personable (usually ;-)
 
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