exhaust backfire and engine missfire

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fbrillou

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Aug 9, 2013
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Tongeren, Belgium
Hi guys, since the last time I visited there have been some major repairs on my 05 Raptor. A new piston was installen, together with new crank and con rod bearings. It ran fine for a while, but then it was hard to crank and it didn't idle smoothly. New stator, new cdi, new crankshaft sensor and it was up and running again. Smoother than it ever was.
Yesterday we went riding through mud etc and suddenly it started to missfire badly on part throttle. Wide open it didn't seem to have any problems and it idled perfectly. After some fiddling with the clutch sensor cable (I pulled it up a bit) it ran fine again. I also noticed that the rubber boot that protects the spark plug cap from water ingress was not completely in place (trying to put it back on with the engine running gave me a bit of a shock). After another rest the atv started back up fine and ran fine for a while when suddenly it started acting up again. A few tugs on the clutch sensor cable seemed to temporarily rectify the problem. However, that cable is not meant to be pulled on and it finally came off. From then on all hell broke loose as it did before. Backfiring and popping and eventually it started to stall whenever we came to a stop. After a lot of cranking I managed to get it started again and I was only able to keep it running when going wide open. Last time it stalled I was not able to get it started again, it cranked fine but would not catch.
I'm going to reconnect the clutch sensor cable tonight, but does anyone have a clue to what could be the cause of the missfire? I thought about a parking brake sensor fault but the Raptor does not have one if I am not mistaken?
 
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