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2004 Rhino cuts out

2K views 6 replies 4 participants last post by  RHINO RAT 
#1 ·
Concern started about a year ago. Drive it a while and engine would cut out like you turned ignition switch off. Would restart right away most of the time and run for a bit and then repeat. Changed plug, new gas, concern got worse over time. Got to the point that would start but only run on full choke but then would stall as soon as throttle depressed. Replaced fuel pump and filter 3 times with progressively better pumps, ending with pump from Weller Racing. No improvement. replaced coil and rectifier with OEM parts, rebuilt carb, and checked all grounds I could find. No improvement. We noticed fuel wasn't pulling through lines even though plenty of vacuum at port. Installed electric fuel pump. Problem solved and ran great -- for about 3 months -- now runs for about 20 seconds and cuts out again, just like turning ignition switch off. Yes, fuel pump is still pumping fuel.

I am stumped. Unit is in too good of shape to give up on it but yet I don't want to keep dumping $$ into it with my parts gun. I hope one of you can help me.


Thanks in advance,
Keith
 
#2 ·
Just had a similar problem, engine would just turn off by itself. Tracked it to a faulty ignition switch. Took it apart and cleaned it out only to have the same fault a couple of months later. Replaced the switch with a new one and have had no more problems.
 
#7 ·
Sometimes the spring in the spark plug cap fails causing intermetten loss of spark.
 
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