Hey guys, have a issue with my 2002 sportsman 700, ive been working on it for a week and cant get to the bottom of it.

Ok so the main problem is it has no power and spits and sputters at full throttle through the intake manifold.
What i have on the machine:
-Snorkels
-moose filter
-dyno jet kit
-running 93 gas
-new spark plugs and caps
-changed oil

This all started recently when i took it out for a ride and noticed it was running bad so i found that the boot between carb and engine was cracked.
I replaced it and still nothing runs like complete crap.

What Ive tried so far:
-Changed the jet and needle back to stock with a 62mainjet checked spark plugs and they were black so to rich.
- with 142main jet the dyno kit told me to install the spark plugs had white tips so im guessing to lean.
- Also switched to 144 and 148 jets and still runs bad
-changed needle height
-changed oil
-Carb was leaking when i noticed the cracked boot so i replaced the needle and seat and adjust the float till gas doesn't come out overflow.

I also just noticed a crack in the y pipe were exhaust escapes could this cause problems?

Im just clue less now someone please help, Thanks!

 

Have you replaced the Ducati igniton system with the updated Kokusan kit? #2202602 around $475.
ALL 2002-to early 2004 carb models were affected and will fail,but were not under any recall! Kit comes with new fly wheel,stator,cdi,coil,reg/rectifier and necessary jumper wires to change over the system.They will either run crappy,backfire through the carb,foul plugs,or as some owners have done is just kill the atv and wouldn't start backup! Think I mentioned this to you in an earlier post! Still probably need to replace the exhaust pipe too! Some I think have updated to the 800 exhaust. OPT

 

okey thanks for the reply but i just checked the compression and both cylinders are at 110? could that be the problem?

 

Just look up all the electrical problems people have had on the early 600 and 700 atvs! I replaced more kits than I can remember,plus there are several recent posts on this problem!! OPT

 

Is there a way i could test the system to see if its causing this?

 

I never had the ignition problem on my 02 sp700 but know others did.

The exhaust donut on the y pipe wears out and will cuase it to run bad and backfire, i went thru that once way back until i got the 800 dual header pipe.

I also had the weathered carb adaptor but it never cracked completely thru, that could cause problems...

Jim

 

Im running 93 octane in it will it still run right? and my compression is 110 and it should be around 150

 

I would just run regular gas.
That compression is low, both my cylinders were both still in the 160s when i sold my 2002 sp700.


Jim