Troubles on the trail

I have a 2009 500 EFI that idles great but sputters when I drive it. I thought it
was the fuel filter, but I changed that and it is still the same. I have also
changed air filter and looked for obvious loose connections and checked fuel
lines for kinks or leaks. It doesn't do it all the time, but it cuts out bad
when it does. It'll run great for miles and then all the sudden it will start
sputtering. It is intermittant and that makes it hard to troubleshoot... I use high octane gas (93). I am so frustrated, it has always ran
great until last week... My next guess is the reverse limiter switch, but I am
just shooting in the dark... Any help would be appreciated!!!!

Could it be that its a 500? lol

Gentlemen, This is my buddy Tim. I told Him if He posted His problem on here We might could help Him out.
Tim, correct me if I'm wrong, but Your machine is a rhino clone and is a 500 efi.
Wasn't sure if anyone has experience with these, but any help would be appreciated !

Clone or not the are similar probably in design. First thing I would do is make sure my jets were totally clean. When do you notice the sputtering? High speed, uphill, downhill, acceleration or cruising. Also check all your coil wiring for loose connections. Let's eliminate one thing at a time.

Also check the roll over valve and make sure its not stuck,it vents off fumes into the frame,if stuck it could cause a flooded condition.

its efi.no jets but it could be fuel pressure maybe..what does the plug look like.water in fuel???

Yes it is a Rhino clone, (Frontrunner). All is the same except the oil filter,... First time I noticed it I was going down hill in low at low speed. When I shifted to high to take off, it started sputtering. It sputtered for a while on flat trail and cleared up when I went for a while. Now it is just sparatic,... It idles great, but when you gas it, it cuts out and loses power. I will check the above. What is the best way to check the jets? Where is the roll-over valve located?
Thanks for your responses!!!

Hey Timbuck, If your smooth with the Firefighter your alright. How easy is it to take the fuel tank off. Maybe there is something in it that is rolling around plugging the feeder-hole off once in awhile? Maybe...

Kenny,
The fuel tank is strapped under the passengers seat, looks like a booger, but I may have to do it...That is a good thought. The tank does have a large cap with the pick-up tube and vent tube. I could take that off and look in. The Dealer I bought it from says he can put it on the diagnostic machine, but I'd rather fix it myself if I can... Firefigher is a good dude!
Thanks!

WV,
Thanks for the info on the jets! Did not realize that. I may drain the fuel tank and put fresh gas in...
Thanks, Timbuck

Tim, on the Rhino's there is a 450, 660 and a 700. The 450 and 660 both have carbs and the 700 is fuel injected. Thats throwing some of Us off. Your machine is a 500 fuel injected so its kind of a mix.

Yeah, it's a 500 yamaha EFI and they make a 700 EFI. It is made by QLink. It's a clone....

timbuck wrote:

Yeah, it's a 500 yamaha EFI and they make a 700 EFI. It is made by QLink. It's a clone....

Yeap, got me when he said it was a 500 I assumed it was carb. Check the fuel pickup in the tank and make sure there are no cracks in it. Did you happen to notice the fuel level, if there is a gauge, when this happens. You may want to change the line from the fuel pump to the carb with a clear line if it doesn't have one so you can see if you are getting any air at times.

I always add fresh gas before a ride, so I never let the fuel get very low at all.

If it's a yamaha clone and efi I wonder if it stores codes anywhere and if there is an easy way to access it through the gauge cluster like on our rhino's.

Could it be a clogged or bad injector?

i dont know why it didnt show my post...but check your throttle position sensor....sounds like it could be the problem

Check plug wire at plug end must fit very tight.had same prob with rhino.james fixed me up.

i would check the spark plug and your fuel first bad fuel can do alot

I called the dealer and I am going to take it in. I can't even get it to run now. He said he can hook it up and check the error codes...He thinks it is electronic. I did check the plug and plug wire, all were good. I was real close to putting a match to it today!!!
Thanks for all the help! I will post what the problem was when I find out....

Good deal Tim, Hope it is something simple. Where is the dealer for those ?

Sounds like a fuel problem, water in gas maybe.

You said, "First time I noticed it I was going down hill in low at low speed. When I shifted to high to take off, it started sputtering. It sputtered for a while on flat trail and cleared up when I went for a while."

Water and gas will not mix so to speak and they stay somewhat separated in the tank, kinda like oil and water, sometimes big globes of water sometimes small globes of water throughout the tank. Sounds like when you went down the hill the fuel level in the tank changed and allowed some of the water to get picked up and entered the fuel line and caused the sputtering, the water can cause it to backfire too. After running it a bit it passed the water through the system only to sputter again when it gets more water in the line, probably picking it up as it's sloshing in the tank.

I filled up my motorcycle one time, tank nearly empty and rode it about 3 miles and it started sputtering and running bad, I tried to make it home but had to trailer it home. It had a lot of water in the gas and it stunk, hard to explain but it had a petroleum kind of odor but it stunk and didn't smell like gas, bet there was a quart of water in that tank of gas.

Smell of it and see if it smells like fresh gas, if not I would definitely dump it and add fresh gas from a different gas station and run it to flush the system.

This sorry gas with ethenol will start breaking down after about 3 weeks and will draw moisture causing the same problems as well as varnish and gumming of your fuel system if it sits unused for long periods of time. I use fuel stabilizers to prevent it from breaking down.
Good luck troubleshooting it and let us know what you find...

I've seen them act the way he was describing because of a hole or crack in the pick line for the tank also. When going down hill will sometimes expose the crack or hole and allow air in the line. Sometimes you just have to eliminate one thing at a time. I would still consider changing your fuel lines to clear. May help you in the future diagnose problems quicker. Good luck.

If all else fails..pour some moonshine in there and see what happens! lol!

Sounds like a fuel pump going bad.