Cj Winds

If the honda has a hydrostatic transmission I would recommend OEM honda GN4 oil, 10W-40 for most hondas 2003 and older and 10W-30 for most 2004 and newer. Hiflo oil filters are a good aftermarket option.

The second nipple that is capped off is another vent, same as the otherside. The carb only needs one vent to work properly. If the fuel pump is bypassed the machine will run out of fuel when the tank gets to approximately 1/3 full (just my guess) Fuel pump is used for when the fuel level in tank gets near level with the float bowl on carb. I would not recommend using an aftermarket cheap carb, they are crap. The fitting is probably for the pulse line on the fuel pump. Rebuild original carb is best

I only repair

I run a small atv repair shop and have a large collection of pdf service manuals. Let me know if you want me to send them your way

I use john deere hy-gard low viscosity to replace demand drive, its the same thing

If some crazy person wants access to all my files let me know how I can share them, I have about 45GB (size) or 93GB (size on file) of info. Looking for someone to organize them and add to them anyway they know how.

Thanks for everyone's input. I am trying to figure out a way to keep it organized and easy to find the right manual. Quadcrazy has manuals listed by make only. Subfolders should have model year or engine size at a minimum

I am looking for help on how to distribute and organize a service manual collection. I would like to use a file sharing website or something similar. I have tons of service manuals and would like to find a better way to add and share these manuals, something that was organized and easy to use. Any ideas would be welcomed.

Sounds like you have no fuel pressure and engine runs fine on starting fluid. Can you remove the fuel pump assembly and place the the inlet sock in a tub of fuel and watch if the pump works and if there are leaks anywhere?

Yes compression numbers are low because of the decompression system. You should never mess with the throttle speed on an fuel injected atv. If engine idle is not within spec then there is something wrong. There should always be a small amount of free play with the throttle but this does not seem to be the problem. The problem is most likely the iac valve or a vacuum leak

The problem lies with the aftermarket ignition key switch that was replaced, find an oem key switch

Try buying a used OEM carb from a suzuki or arctic cat 300 with the suzuki motor. You should always rebuild a used carb bought online

Rotella 5w-40 t6

Most Chinese carbs don't work right out of the box. If they do work, they only work for a year or two. Chinese carbs cost $20 to $60. OEM carbs are $200 to $600. Most of the time the best option is to rebuild the OEM original carb. DIY cost is about $30, carb rebuild at a reputable shop is $200-400, cheaper if you bring just the carb into the shop.

To test the charging system, first check the battery voltage while the engine is running. If voltage is lower than 13Vdc then rev the motor in neutral to about 3000rpm. If voltage is still lower than 13Vdc, find the large 3 wire stator charging connector, 3 large yellow wires kindy near the battery on the left side. Check AC voltage on the yellow wires. There should be 3 different tests, first test pin 1 and 2, then pin 1 and 3, then pin 2 and 3. Take readings while engine is reving around 3000rpm. Yellow wire voltages should be over 25Vac for all 3 tests. If yellow wire test is good then the problem is almost always the voltage regulator.

Most likely its the regulator located behind the front grill or under the front rack.

The recon has an oil filter rotor that probably should be cleaned every 10 years or so, to access it you need to take one of the crankcase side covers off, I forget which one

It is located near the front left tire

The voltages spec'd are when engine is cranking. Test the voltages with a dva adaptor. Test trigger and pickup coil for dva voltage and resistance, also check if there is resistance to ground with each wire. I have seen several junk new flywheels installed in this engine so be aware.

Please check the magnets on the flywheel, if magnets are loose than replace flywheel. This is a very common problem on the suzuki 400 motor

The kit for a 2003 AC 500 is 26-1059 2000-2002 uses 26-1061 2004 uses 26-1058 Make sure the vin's 10 digit is a 3 to symbolize 2003 model year

It seems off but hard to tell. Did you install the carb boot that attaches to the cylinder head or was it already attached? Is the carb completely pushed in the boot?

I believe its a fuel primer. Very few utility atvs have accel pumps on the carb.

The lever does not attach to anything. If carb is leaking at top of bowl then the bowl gasket is prolly leaking.

The threaded hole on the bottom of the carb is a place to screw a bracket down that holds the idle adjustement knob