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4x2 Intermittent stalling will restart after sitting a while
Long story short. I work for a software company and because I put myself through school as a GM and Peugeot mechanic I was asked to look at a 4x2 Gator that the company owner uses on his property.
When I first looked at the unit it would run for a while and die. I confirmed the fuel pump was not working and replaced it. While I was in there I replaced all the fuel and vacuum lines on the fuel circuit and replaced the spring clamps with hose clamps.
I also added a fuel filter on the line coming out of the tank to the pump and from the pump to the carb. There were no filters prior.
The unit ran for a while and started dying again. The guys said it was after going over bumps or driving parallel to an incline. I pulled the float bowl and is had at least 1/8" of rusty crud in the bottom. So I cleaned it and sprayed float area with carb cleaner. The carb was not removed.
I sat with the thing in neutral and WOT for over 30 minutes with no issue. I then drove it, smooth surface, for another 20 min with no issue.
Come in today and it had stopped running coming across a field. I drove over to it, cranked it and it would not start. The guy using it says he waited about 15 min, cranked it twice and it fired up.
When this has happened in the past, I have pulled the plug and it is dry. I have got it to fire by spraying some carb cleaner in the intake. Confirmed there is spark so I'm leaning towards fuel delivery. As it is so intermittent and it eventually restarts, I'm thinking the float or valve is getting stuck but of course when I pop off the float bowl, it is down and moving freely.
Any other thoughts here would be greatly appreciated.
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4x2 Intermittent stalling will restart after sitting a while
Update. At the moment it is not getting any spark. Diagnosing the key switch as now the guys are saying they have had to jiggle the key a lot.
So nice of them to give me all the info up front.
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4x2 Intermittent stalling will restart after sitting a while
Swapped key switches with his 6x4 and got spark. Then cleaned the plug and connectors on the original switch from the 6x2 and got spark.
It fired up and they are driving it again.
Wonder if I've been dealing with two intermittent problems all along.
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4x2 Intermittent stalling will restart after sitting a while
End of day update. The guys said they had an issue with it dying and not restarting again. This was after I swapped the key switch from a 6x4 over. But note this is an older unit as well.
One thing I noticed with this key switch is that on occasion you can turn the key to start, hear the solenoid click but the starter does not rotate. If you hold the key in this position for a while it will sometimes begin to rotate. Other time you just release and turn the key to start.
I drove it for about a half hour tonight and could not get it to die. I did sputter/bog down twice in a row but then continued to drive for another 10 min before I decided to park it.
I then just sat in place for another 10 minutes, starting and stopping it. On numerous occasions I got the key position issue but eventually got the condition where it would crank but not start. At this point I pulled the plug wire and tested with a known good plug and there was no spark.
Any thought here would be appreciated. Thinking of replacing the key switch next. The solenoid is a new unit from stock.
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4x2 Intermittent stalling will restart after sitting a while
I believe your main problem is the ignitor. If you have an older model 4x2 it is the little silver box on top of the motor with the black wire plugged into it. If it doesn't have this box the ignitor is in the coil and you have to purchase a new coil. I would replace the ign switch too, they aren't too costly.............I have had the same solenoid problem. The solenoid ( new ) would just click with the ignition switch, but if I went to the solenoid and pulled the small red wire back far enough to jump power from the 12v lug on the solenoid to the spade connection with a screwdriver it would turn over every time.
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4x2 Intermittent stalling will restart after sitting a while
Thanks for the reply. Looks like we have a bit of a grandpa's hammer issue here. If you know that old joke.
These units were purchased in 99, since then they have had the frames and engines replaced.
Turns out this unit has a FE290D-FS08 motor that according to Everglades (vendor) was never used in the 4x2. Only the DS, AS, CS and 26. The owner recalls purchasing it from ebay.
I don't see an ignitor externally but a parts sheet on-line for a BS03 shows one of two models near the coil pack.
For a start he is going to order in new ignition switches as that is the cheapest way to test the intermittent behavior.
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4x2 Intermittent stalling will restart after sitting a while
If you can't see the ignitor on top of the motor, it doesn't have a separate one. Some of those on line pix have an ignitor pictured that is not compatible with the Gator. You will have to go with the new style coil. Also your motor should have plastic fins on the flywheel, older 4x2s have fins cast into the flywheel. The plastic finned flywheels use the newer coil.
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4x2 Intermittent stalling will restart after sitting a while
I know it's been some time on this topic but I wanted to post back that the issue was the ignitor. I went out last month and sorted it out for him. The machine has a new style motor installed. Although the motor was purchased on ebay and the number did not cross in a JD parts book, we were able to get the right coil.
Thanks for all the help.
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07-30-2014, 09:29 
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