I would like to take the time to thank you for your videos. On three occasions now, your "classes" have saved my bacon and taught me what to do with regards to my quad. I am truly grateful.
LOL... I don't think I've heard anyone say "so I replaced the engine, since I had a COUPLE laying around". I mean like I've got some extra nuts and bolts here and there, but an engine... let alone a COUPLE engines? I wish I was your neighbor!
Thanks for the video sir! I only have about 8 hours tied up in this issue right now and no good results. I’m going to try the cdi box. Thanks big help.
I was having issues in my previous comment a couple of days ago about the fan not engaging in engine overheating did exactly what you said. It worked perfect thank you very much but I’m still having the problem with the throttle up coughing and barking. I just watched your CDI box replacement video. I’m gonna give it a try. Thanks a lot for your help brother I sure appreciate you, this is CJ out of Minnesota
I decided with all the free time I had along with the rest of the country ... I would do a little wrenching at home in my shop. So took in a polaris 400 year 2000. Been through everything couldn't find out why its popping heavily through carb. Found your videos on these things. They have been a ton of help thankyou! I have the valve cover off now for a cam inspection.. If it's not that I am going directly to cdi! I told the owner who told me when he dropped it off I didnt think it was a carb issue. Sounded electrical..
Man no shit!!!!!!! I just spent a grand on a carb an new exhaust. Like u hours and an hours of spent time. I just ordered new cdi box. Since new this 90cc can am dsx has been a bloody nightmare. I’ll get back when I get part in. Thank you soooo much. Peace!!!
Thanx for all your vids. I have a 99 sportsman that needed a cam. watched your vid and completed repair. Started up fine and idles great. any throttle input it dies. bought the air screw adjuster tool and have fiddled with it endlessly. i can get it to make revs but once shut off and cooled down the same thing happens. once i get it to rev it runs great but will not go slow. as soon as i get out of the throttle it bogs and I have to choke it to keep running then it will rev great again. I have checked everything a dozen times. Bought new carb off amazon and same thing. also put a new carb boot on it. same thing. I am stumped.
Thank you for posting this. It got me on the right track! My 2013 Polaris Ranger sxs 400 H.O. Idles fine but spits and spudders when throttle is increased. I was about to tear into the carb, but will try this fix.
Exact same problem. 2009 Sportsman 500 HO. sputters at 5500 rpm. I did replace the carb with the Amazon $38 one. Not fixed. Returned to Amazon (make sure you get the carb that says "free returns" or you'll be paying shipping). Put old carb back on. Then I replaced the two fuel lines on each side of the carb from the fuel pump and the vent tube on the right side that goes to the frame. That worked!!!! No sputtering or bogging down. I also tried the starter fluid spray on the carb boot and nothing happened so I figured good boot. I didn't believe you on the hoses replacement. But I sure do now. Thanks so much for this video. I must have taken that old carb off 7 times trying different things. Thanks again!!
@@TitaniummanGarage After 2 days I'm back to the same problem. it idles fine then when you hit the throttle it dies. I probably need a CDI box. The OEM price is $400. I'll try the after market ones first and see if that fixes the problem.
@@TitaniummanGarage my quad has everything new has spark and start some times few seconds and die , i pure new CDI and start and rev up like a champ thanks my yamaha was sitting in my garage for 18 months
Thanks for this info. I've got a 400 that's doing the exact same thing. I've swapped carbs, rebuilt carbs, etc, etc. I'll try this before I push it out back and set it on fire.
Thank you. I have a Polaris Phoenix 200 doing the same exact thing. Completely cleaned the carb and still doesn't run right. Ill have to try a new CDI box, thank you!!
Thank you for this video! I've tried everything I can think of... Spark, Air & Fuel and my poor girl still bogs out while accelerating!!! I'll let you know how it works out :)
I just ordered a CDI box for my 500 based on this video hopefully that works. I also have a cheap aftermarket carb on there and was thinking of rebuilding the original mikuni with a mikuni kit but I can't seem to find one. It's a 96 sportsman 500 and I just cannot find what mikuni model that is. The numbers on the carb don't come up with any kind of search mikuni's own website doesn't list anything for a Polaris that old. The part number out of the Polaris shop manual doesn't bring up any results. And I'm having the same issue at idles just fine but it bogs down and dies when you try to do anything unless you get moving then it'll go at wide open throttle. Cam is good replaced the rockers they were worn timing chain was loose that's brand new. Has good compression I tested it with the compression override and without. With im getting about 80 psi and without I'm getting around 170. Could you help a brother out so I can get that proper rebuild kit ordered I don't like using Chinese aftermarket kits. Also it's pretty often that it won't shut off I unhook the black wire off the the one box that made no difference but I did notice if the ground wire for the cluster is not hooked up none of the instrument lights work and I get feedback through the gear selector to the headlights they shine dim and they change high to load depending on the gear you're in ground back up and everything works properly so I'm not sure if that's related somehow. Thanks for the videos you're like the only guy on UA-cam that seems to know what he's talking about I watch every one of them keep it up.
I am working (Infrequently) on a 96 sportsman. Just put the new spark plug wire in today and mounted the coil in front of the tank where the old one was- cannot find what gets plugged onto though. Meaning I’m not sure if its a red wire and if so where that is at? If you had a quick suggestion we would appreciate that. We looked at the diagrams we have but they are not helpful. Thanks for your time. Payne
Check the ground wire coming off the spark plug coil as well. Sometimes the cheap ground wire breaks coming off of it and it keeps the top end from sparking properly and in sync. That’s a huge problem with these and it’s an easy thing to pass over.
Question for you - I have a 2000 Sportsman 500. Just a little history. Back in summer had to replace the starter. Did that but then noticed that the carb was leaking gas. Pulled the carb and rebuilt it put back on and started fine. I then pressure washed it. Might have been a little aggressive with
i wonder if you just had a short in your wiring that was fixed by reconnecting/moving wires around. i believe that has a rev limiter circuit that gets engaged only when you hit the throttle, if that was shorted it would kill it the second you touch the throttle.
My friend, you have to tune the carburetor, look at you spark plug to see if it is running lean or rich, in your case most likely rich. You should adjust the jet by moving the clip in the jet in the carb up a notch, the use the air/fuel screw next to the intake on the carb until it runs fluently. You can also adjust the idle screw as needed because it will need it after changing the air/fuel ratio. Hope this helps!
well it’s not the carb it is sadly an electrical issues, had the same problem with my suzuki vinson 500 yesterday and was trying too fix it, i took the whole carb apart, and cleaned everything, we tuned the carburetor over and over, and nothing changed, we give it throttle and it would die, i’m pretty sure this guy knows what he’s doing if he has a “few motors laying around”, not saying you don’t know your stuff, just saying you can still learn something new, even when you thought you knew everything 👍 i appreciate this guy for the video, i just put in a order for a (OEM cdi unit) and a (OEM Carburetor) i’ll replace the cdi before the carb and i’ll let you know how it goes💯
@@StyFreshhey I have a suzuki vinson 500 aswell and I'm having the same problem I'm yet to take the carburetor out but I'd like to hear what was wrong because one of my fuses attached to my battery was blown so I'd like to know how yours went!
@@anyabsentjarl6196 honestly it’s still sitting there not running I was planning on towing it home and working on it I’ll let you know soon! Someone lie my car on fire tonight lol
I have a 2001 Polaris Sportsman 500 HO, just got it 2 weeks ago its been well taken care of from the previous owner, was doing fine until yesterday. It cranks up just fine put it in forward and goes just fine, when I shift into reverse it just cuts off, I was thinking it could be something electrical too, I find that to be strange, if you have any advice or help I would greatly appreciate it. take care
I just got one of these and I'm troubleshooting. Something driving me nuts. The brown wire from the stator to the ignition coil has a pigtail with female spade connection. I cannot figure where that thing goes. I see in your video it is just kinda hanging out there too. Does this thing go nowhere? Is it Polaris' cruel joke or had you just not gotten around to reconnecting it. If it is the latter, could you please help a poor soul and tell me where it goes? Thanks
I Have been trying to get an 09 sportsman 400 HO figured out for over a year. Only has 60 hours on it! A dealer serviced it for my friends widow and charged her 1200. Dollars to put a battery in,change oil ,and rebuild carb! They gave it back to her and it still ran like it has water in the gas slash clogged fuel pump! I got it running ok with fuel system cleaner and it wad running nice! Out of no where starts popping,tries to die out. If you put the choke on it'll keep running but badly . An hour later it may run fine and give you no problems for couple days.Always pulls it funny stuff at inopportune times. Took carb apart ,cleaned thoroughly, and machine ran great for a day . Thought it was fixed . Started dying out again on me ! So put new fuel pump on , still running lousy ! I am starting to think electrical . Gonna take the plastic off front and see if any wiring bad under the front deck box on top! It either runs perfect or runs like shut!.Black and white wire from coil and brown wire from coil go up under the front plastic..Maybe a wire corroded or something. If I don't find bad connection ,I think ill change coil.out first than think about control.modules!
Your on the right track. The fuel system is ruled out. One thing to check is the safety shutoff switch by the thumb throttle. If the contacts are close to touching the ride could trip it. If they are touching it will shut off. The reason I say that is after you pull the carb, clean it, put it back together sometimes it gets over looked. especially if the cable was removed from the carb and not re adjusted. Also check the choke adjustment. Just a couple quick checks before you dive into the electrical. But yes electrical would be my next guess. check the plugs by the kill switch too. see if there are any corroded wires there as well.
Hi can you help me i bought a 1996 sportsman 500 but i need to know where the coolant sensor wire goes and where the radiator wires go or come from please help
In case someone revisits this thread. Sportsman 400 would die with throttle. I was troubleshooting the fuel pump and placed my finger over the vacuum hose and felt suction. It instantly started idling higher. I adjusted the idling and reassembled the fuel pump and it now runs great. I think covering the vacuum hose with my finger created extra suction in the carb or hoses and unclogged something. I also have an aftermarket carb with a hose cap on the top that was cracked. All fixed.
Would the exhaust gasket need to be replaced ? My exhaust sounds like it’s going to blow up pushing full throttle and sounds like it’s sputtering backfiring after I let the throttle off. Front header pipes turning blue. It won’t accelerate past 60mph and bogs down, I’m guessing it maybe an exhaust gasket leak in the front? Vstar 650
Cam, carb, pick up coil, fuel pump, built three 2 had those issues the throttle body plunger also needs to be seated and the air box and hoses need to be hooked up
Thanks, for the information. I Have a 2002 Sportsman 500, and Mine will fire up just fine idle ok, but once I let off the gas after per say moving it around it dies or doesn't want to keep running. If I keep my thumb on the throttle it does ok, but this last time I thought I could smell oil, but I didn't see any signs of a leak and the oil level still says full. any tips?
Peel back the throttle cable boot and tighten that up a bit. Should notice a difference. If that doesn't to the trick try adjusting the idle with the set screw on the carb.
Hey there I have a 2014 sportsman 570 ho that starts at low RPM's and dies sometimes when cold Low idle RPM's when cold But idles and runs good after warm up Only low RPM's when cold I already cleaned carb. Play with throttle cable and still have the same problem, What could it be?
You could bump up the idle screw. there air/idle screw at the bottom of carb near the boot. It might have a round plate over it so people don't mess with it. Its usually a turn and a half to two turns out depending on the altitude you live in. You could try that.
I've got a 97 Sportsman 500 that just seems like it's out of time and I've done all of the steps you're supposed to do to make sure that it's in time and replace the cam with an aftermarket. I've got plenty of spark but when I add fuel to it it backfires out of the carburetor. It acts like it's out of time but I've set it twice now and changed the carb trying to trouble shoot, still out of carb. Good spark and motor has low hrs on it, seems crazy to be cdi? It had the idle fall on its face before the no start backfire carb thing. Gonna chk cdi, fingers crossed.
I am having the same problem. Has been ongoing for more than a year now. I am pulling my hair out on this one. 97 Sportsman 500 that ran great and then slowly started running poorly. After a carb kit, after market carb, adjusting the valves and checking the cam, new fuel pump and china cheap cdi, still does the same thing. Idles fine, but when you pin the throttle it acts like its running lean, backfires and runs like shit or dies. I guess I will try a polaris cdi and see if that fixes it. About ready to junk this thing.
I feel your pain. I went through the same thing with a magnum. Try pulling the black wire on the cdi to see if that makes a difference. Make sure your at top dead center. Check out my latest video..I found a better way to get it there. Did you check your breather hoses for cracks or kinks. One goes to the bottom of the case the other to the oil res. and back to the airbox. One of the big issues..especially with 97 and 98's are too much air getting in and making it backfire. Is the airbox cover warped? If so that will suck in more air and make it run lean. Also check the carb to head boot. I had one that had a hair line crack in it. I didn't see it until I pulled it off. Once I replaced it my problems went away. Hope that helps. Don't give up. Oh..and those Chinese carbs usually only last a year. fyi. Good luck.
I don't know if this will help. I have a 2004 330 polaris magnum and started acting like your polaris. Would idle fine but when you gave it gas it would spit and sputter going forward but when I pushed in the reverse override switch it ran perfect. So I just unplugged the transmission switch plug and now it runs great. Even in reverse there is no need to push in override switch. I believe the transmission switch is bad and telling the machine it was still in reverse when going forward.
I have a 2008 Sportsman 500 HO/EFI machine that does the same thing - idles great - revs up - if I put it in gear and hold down the brake - I can rev it up - but if I release the hand brake and start to move forward - the machine dies immediately. I replaced the voltage regulator and no change. I ordered another ECM module, but it has been on order since last Nov. - 2020!! I am 90% confident that this is my issue, but need to find if there are any used or rebuilt ECM modules for a 2008 machine out there - or if there is a company that can refurbish my ECM module.
Hm thanks for the video. I have a can am that has done this since I bought it, same thing except sometimes it just bogs down, other times it dies. Sometimes it does the same thing when the throttle is about to be let go, would it still be that part?
My brake light is not working. Should I remove the crankshaft bearings check the timing and replace the reverse gear cog? Just kidding, I find your videos very helpful and don’t stop making them please. PS you could always do a voice over for Mike Rowe!
I just bought an 05 Honda foreman 500 with this same issue. Guy I bought it from put a new carb, new fuel lines, fresh gas. Should I start with the cdi box?
I have an 03 sportsman 700 that's doing the same thing. I changed the cdi and still doing it. Idk what to do next. I've changed carbs, the boot, coil, fuel pump and cdi. It idles perfect, but boggs immediately. You can choke it and it can rev higher. You can block some air flow thru the carb and it'll rev higher.
I have a very similar issue. Starts and idles well. but when throttled past 50% it dies. However, if I baby it past 1/2 throttle very slowly it makes it to full throttle/RPM. I thought fuel pump. replaced, and same problem. Now I think there is something restricting the fuel line. Pulled the tank and found varnish particles. Is there a filter inside the tank? Looks like a grommet there that I do not want to force out and break something.
Thank you for the reply, I will try the soft magnet, but I think that bolt may be too heavy for such a magnet, and it may even be jammed against the lower Timing Chain sprocket. It is not going to be easy. Thank you anyway. Franklin
Hello, so far I've liked your videos. I do have a question about a 2005 Polaris sportsman 500 HO that I'm having problems with. I had overheating issues with it at one point which ended up being my plugged radiator but in the meantime it now will start and idle but will not rev up. Do you think you would still be the CDI? That would be the problem? Thank you for your videos
Did pulling the choke out seem to make any difference when it was running? That’s what mines doing. Idles fine, falls on its face when gas is applied. Pull choke and it will take probably a 1/4 throttle. My guess is a plugged main. Thoughts?
Hey Titaniumman - thank you for the video and info. I have an 07 Polaris Sportsman 500 EFI that has a similar problem. Starts up fine, idles fine but you have to be gentle to start rolling otherwise it stalls out. It will also bog and feels like not enough fuel is getting to the motor when at 35 mph. Any suggestions or recommendations? - thank you
@@krisfrench8648 not yet.. I haven't had a chance to get to it. It runs but the stalling and backfires are annoying... But I am planning on rebuilding the fuel pump. You cant buy a new pump alone but there is a rebuilt kit available. I also noticed I was missing 2 of 4 airbox clips, so I will be closing the airbox tightly as soon as they arrive. I dont think it's the issue, but you never know.
@@paulpolanowski9660 did you get your problem fixed, I have the same problem, i had it in the shop (polaris dealer) they replaced wiring plugs going to the tps , iac, and map sensor. then called and said the power distribution box needed to replaced, and that would fix it.. nope it did not. after spending $1200 dollars i still have the same problem .
I’ve got the same problem .. I ordered a new cdi box and it does the same thing .. might be because it’s not an original oem Polaris cdi box . China box
I have a 330 Polaris Magnum, runs almost perfect without the air filter top lid on, as soon as I put the lid on it still idles fine but will not throttle up. Any help would be appreciated!!
hey i just had this problem! i put my hand over carb and it finally took and started a little, then i played with the throttle while doing it and it was the etc
Hi I have a question you might be able to answer for me I have a sportsman 400 2x4 2012 I bought as a project it had grabbed a piston I have sorted that but it’s got a few minor problems one is the vent hose is off can you tell what colour the one way valve on fuel tank vent goes on to tank and what and where the tube is routed to and also does it have a filter on the end I would be gratefull if you could help thanks
Hey, enjoy your video's. I've got a '96 or 97 425 Magnum 6x6 that's been getting to be a weekly pain in the %&*, just little crap, but all the time. I have a little hobby farm outside Amery and its really needed for plowing and hauling. It's a real work horse. Engine seems fine and starts great, so with the prices of new being so much, I'm considering a frame off resto this summer. Plastic is good just faded, solid frame, most rust is just surface stuff. I figure even if I have to get into the engine, I could probably get another 10 years out of it and it would be worth it. Bring it back to almost new, Paint, new decals, bed liner paint, polish the plastic etc. I'm planning on shocks, cv's, front ball joints and tie rod ends, rear shock, rotors and pads. Rear and front wheel bearings and bushings. Chains and sprockets if needed. Clutch seems to be slipping a bit going up hill while plowing so maybe that also. When I had it into a Polaris shop they test rode it and said the engine felt good. I'm not afraid to throw a couple thousand into it and do all the work my self. After market stuff seems to be all over the place. I was even able to find a new front chain eccentric last year.I bought an owners manual and found the service manual on line, but your video on converting a 425 to a 500 I've book marked! Is it cool to contact you for answers from time to time? You really seem to know these old Magnums.
Thanks. Not sure why some messages are not showing up. I just saw yours now.Thats cool. I like to hear people rebuild them. Around here everyone is parting them out. Soon there will be none left.
Why was your first thought to pull out the camshaft? And then replace the motor? Like those seem like extreme things to do! You should have started with carburetor then CDI box and you would’ve found the problem right away. Always start with the small stuff and then work your way to the big stuff.
Good tip for the viewers. The reason! Because the last 3 500's I had was either a bad cam,chain or timing was off. This 500 the chain timing chain broke. I had just learned the cdi works at idle and not at full speed. That's the message I was passing along. Great comment I suppose to a new viewer it would sound extreme lol.
Hi, do you happen to have a good CDI box that fits a 2003 Polaris Sportsman 500 HO? Would you be interested in selling it to us? I also need two right footwells and 3 rear brake master cylinders. Please let me know if you can help! Thank you for your instructional video.
I have a 2006 EFI that starts and idles but when I give it gas it misses and runs like crap, as the rpm rises it seems to run ok. What is up with that?
@@jerryforeman4020 I suspect the throttle position sensor but I don’t know for sure. I need to take it to the shop for service but I have had so many things going on at home like building a decent wood shed and a new steel roof on the chicken house. I need to get it repaired before winter sets in for sure. Trying to set myself up for the coming winter and need my Sportsman to get firewood from the shed to the house.. I will do my best to post up when I find out what is going on.
@@jerryforeman4020 Hey Jerry! I went over to the not so local Polaris dealer today and bought a new battery but it didn’t help the throttle issue. I did speak with a service technician and he suggested that it might be the in tank fuel pump but I don’t think it is the pump. It seems to run strong but there might be a crack in the internal fuel line. I will give that a shot tomorrow. I have been a Ducati rider for many years and I have intimate knowledge of fuel tank internal fuel pumps. The tech suggested replacing it but you have to buy a whole new fuel tank to the tune of $750.00, that is not going to happen here. I will keep you informed. :) At least now I can use the thing.
@@TheSagerider ahh okk I have a 2008 Honda rancher and there really isn't a video to help me out so if you can find a problem to the throttle like if you give to much it just shuts off then maybe it's a Honda problem aswell because with the Honda it's already got a new fuel pump and the filter had been clean and you can get it up to speed but again to much throttle it just shuts off and I'm clueless at this point
I got a 2012, just put a carb on it and the fuel pump thing that’s not actually a pump and it still runs like crap, it idles and starts up awsome but when you give it gas it doesent die but is won’t rev up at all
Maybe you got a bad carb. it sounds like the diaphragm isn't opening correctly. I would take the top cover off the carb and inspect the rubber diaphragm.
Thank for all the videos i have a 04 sportsman 500 same problem Installed a $ 30 cdi same problem will not rev quick this machine has 780 hours at what hours do you see cam shafts worn , and thanks again
Depends on the year. 97 to 99 had soft camshaft. Around 2500 to most of them being 5000 miles. It's rare to see a 2001 with a bad cam unless something else caused it. Low oil or overheating.
@@TitaniummanGarage sir once again thanks for taking the time to help me out . Unfortunately I cant find the a red box one that fit a 04 sportsman, the ones i saw have pig tails coming out of it if you a have a seller name or a item# that would be awesome, i did find a couple of used ones , if you have a PayPal account i will compensate you for your time THANKS
@@stansimpkins6439 Sorry...My bad. I was thinking you had an earlier model. You have what I call the plug and play style. I don't have any. But if you can find a good used one I'd buy it. Check out Powersports nation.
The cheap China cdi should have worked, but some are actually and others are DC. There's a guy on UA-cam who shows how to convert any bike to DC then wire it up to the battery. Boom it works every time. I bet you you put a DC with an account current and fried it right away. The ac current coming off the stator is like 50v vs. 12 v DC. Anyhow, my electric water pump came in last week and this video just got me pumped up enough to go put it in.
I'm having the same problem with my 02 500 HO. It's bizarre, some things seem to fix it, put it back together then before long acting up again. It's ripped apart in my garage now. The problem is finding someone who has the same wheeler that will let you try parts. This has been going on almost a year now, very frustrating. Cam is perfect, Aftermarket coil, aftermarket carb. Ran awesome then started acting up after I parked it!!!!!
@@kmisercola7180 Yes that's where the Rev limiter is built into . I am here looking at stuff because I have a guy who is having issues with his & says it hesitates now a few months after he had someone rebuild the carburetor & adjust the valves which he seems to think he set them too tight . He hasn't brought it over yet because I am working on another friend's custom built chopper that needs a new starter so I haven't been able to hear the Polaris run or drive it to see how exactly it's running but from what I hear these Polaris ATVs are known for several problems especially the cams & cranks going bad in them & I also read that Polaris had a big contract with the military for the army if I remember & the army backed out because they were having all kinds of problems with the cams & crank shafts going bad in them & being they need to use a dependable product those issues couldn't be tolerated . I had a 91 Polaris 350L liquid 2 stroke for about 8 years that was used mostly as a work horse on my property & finally sold it but to tell you the truth I would never buy a Polaris ATV again after seeing how mine was designed & how poorly the fit & finish was on things on it plus another friend of mine who had a new Polaris just a year ago & his engine started knocking so he sold it as well & bought a CanAm instead but if it were me I would probably buy a Honda or even the newer Yamaha Grizzly's are pretty well made with not as many issues as these Polaris ATVs seem to be plagued with .
I am working on a 500 sportsman that is stalling upon acceleration. Cam looks good and it idles perfectly. Tried a different carb and cdi with no luck, I also isolated the fuel pump and gravity fed fuel with a gas caddy, still no luck. What I have discovered is this, if you the take the air filter out, and block the intake with a piece of cardboard till it dies, it will start back up and rev up just fine for a second or two. The airbox is jacked up, and only has one screw holding it down. Valves are at spec. Anyone have any input on this?
@@TitaniummanGarage yes, I have disconnected the cdi ground per the manual and have visually inspected the boot as well as spray it while running to see any changes.would the vents going to the air box or the one from the carb to the oil tank cause any problems like this?
I have a 2001 Sportsman 500 ho. Starts and idles fine. When I ride it, it pretty well tops out at 15 mph, slows down I.der anyoad and starts popping out the exhaust. I changed the carb, and put a new plug in it. No change. I'm hearing that these machines are pretty sensitive to intake air volume. Any known issues with these? Cracked carb boot? I'm about to sell the thing if I cant resolve it. Frustrated.
That's correct. If you have cracks in your breather hoses or airbox it could cause problems. Have you checked your cam and timing? It sounds like a timing issue.
I would like to take the time to thank you for your videos. On three occasions now, your "classes" have saved my bacon and taught me what to do with regards to my quad. I am truly grateful.
LOL... I don't think I've heard anyone say "so I replaced the engine, since I had a COUPLE laying around". I mean like I've got some extra nuts and bolts here and there, but an engine... let alone a COUPLE engines? I wish I was your neighbor!
Ha ha ha. Your not the first person to say that.
Thanks for the video sir! I only have about 8 hours tied up in this issue right now and no good results. I’m going to try the cdi box. Thanks big help.
I was having issues in my previous comment a couple of days ago about the fan not engaging in engine overheating did exactly what you said. It worked perfect thank you very much but I’m still having the problem with the throttle up coughing and barking. I just watched your CDI box replacement video. I’m gonna give it a try. Thanks a lot for your help brother I sure appreciate you, this is CJ out of Minnesota
Awesome man! Glad to help. Good luck.
Exact same issue with my 2002 Sportsman 400, you are right on spot, the CDI did the trick!
it’s like 500$ for my suzuki vinson 500
I decided with all the free time I had along with the rest of the country ... I would do a little wrenching at home in my shop.
So took in a polaris 400 year 2000.
Been through everything couldn't find out why its popping heavily through carb. Found your videos on these things. They have been a ton of help thankyou!
I have the valve cover off now for a cam inspection.. If it's not that I am going directly to cdi!
I told the owner who told me when he dropped it off I didnt think it was a carb issue. Sounded electrical..
Your on the right track. I would do the same. Thanks for watching. I'm glad to help.
Man no shit!!!!!!! I just spent a grand on a carb an new exhaust. Like u hours and an hours of spent time. I just ordered new cdi box. Since new this 90cc can am dsx has been a bloody nightmare. I’ll get back when I get part in. Thank you soooo much. Peace!!!
No problem..good luck. Hope that solves the problem.
Thanx for all your vids. I have a 99 sportsman that needed a cam. watched your vid and completed repair. Started up fine and idles great. any throttle input it dies. bought the air screw adjuster tool and have fiddled with it endlessly. i can get it to make revs but once shut off and cooled down the same thing happens. once i get it to rev it runs great but will not go slow. as soon as i get out of the throttle it bogs and I have to choke it to keep running then it will rev great again. I have checked everything a dozen times. Bought new carb off amazon and same thing. also put a new carb boot on it. same thing. I am stumped.
Thank you for posting this. It got me on the right track!
My 2013 Polaris Ranger sxs 400 H.O. Idles fine but spits and spudders when throttle is increased. I was about to tear into the carb, but will try this fix.
my scrambler 500 is doing the exact same thing with two differnt carbs, give it throttle, kills it! thank you for the info!
Did you manage to solve it my friend ?
I am going to look at that first thing cause my husband has no clue what it is thank u very useful info.
Exact same problem. 2009 Sportsman 500 HO. sputters at 5500 rpm. I did replace the carb with the Amazon $38 one. Not fixed. Returned to Amazon (make sure you get the carb that says "free returns" or you'll be paying shipping). Put old carb back on. Then I replaced the two fuel lines on each side of the carb from the fuel pump and the vent tube on the right side that goes to the frame. That worked!!!! No sputtering or bogging down. I also tried the starter fluid spray on the carb boot and nothing happened so I figured good boot. I didn't believe you on the hoses replacement. But I sure do now. Thanks so much for this video. I must have taken that old carb off 7 times trying different things. Thanks again!!
Been there! Yup, its vacuum operated. So if the lines are weak..they collapse.
@@TitaniummanGarage After 2 days I'm back to the same problem. it idles fine then when you hit the throttle it dies. I probably need a CDI box. The OEM price is $400. I'll try the after market ones first and see if that fixes the problem.
Did you try adjusting the choke cable at all. I just had one with the same issues as yours. I tweaked the choke a little then it was fine after.
I really needed this!!
MEN THANKS FOR THE VIDEO THAT FIX A PROBLEM WAS DRIVING ME CRAZY
Nice! Glad it worked for ya. It drove me nut too until I figured it out. Happy to help.
@@TitaniummanGarage my quad has everything new has spark and start some times few seconds and die , i pure new CDI and start and rev up like a champ thanks my yamaha was sitting in my garage for 18 months
Thanks for this info. I've got a 400 that's doing the exact same thing. I've swapped carbs, rebuilt carbs, etc, etc. I'll try this before I push it out back and set it on fire.
Hahaha! That's how I felt about this one.
did it work
Let us know if it worked out for u also
@@Glucoperon yes
@@tava7902 yes it did
Thank you. I have a Polaris Phoenix 200 doing the same exact thing. Completely cleaned the carb and still doesn't run right. Ill have to try a new CDI box, thank you!!
Thanks buddy I just watched it and hopefully that will help me, seems to not go when I gave it gas
Thank you for this video! I've tried everything I can think of... Spark, Air & Fuel and my poor girl still bogs out while accelerating!!! I'll let you know how it works out :)
did it work
Thank you. The videos help a lot
I just ordered a CDI box for my 500 based on this video hopefully that works. I also have a cheap aftermarket carb on there and was thinking of rebuilding the original mikuni with a mikuni kit but I can't seem to find one. It's a 96 sportsman 500 and I just cannot find what mikuni model that is. The numbers on the carb don't come up with any kind of search mikuni's own website doesn't list anything for a Polaris that old. The part number out of the Polaris shop manual doesn't bring up any results. And I'm having the same issue at idles just fine but it bogs down and dies when you try to do anything unless you get moving then it'll go at wide open throttle. Cam is good replaced the rockers they were worn timing chain was loose that's brand new. Has good compression I tested it with the compression override and without. With im getting about 80 psi and without I'm getting around 170. Could you help a brother out so I can get that proper rebuild kit ordered I don't like using Chinese aftermarket kits. Also it's pretty often that it won't shut off I unhook the black wire off the the one box that made no difference but I did notice if the ground wire for the cluster is not hooked up none of the instrument lights work and I get feedback through the gear selector to the headlights they shine dim and they change high to load depending on the gear you're in ground back up and everything works properly so I'm not sure if that's related somehow. Thanks for the videos you're like the only guy on UA-cam that seems to know what he's talking about I watch every one of them keep it up.
I am working (Infrequently) on a 96 sportsman. Just put the new spark plug wire in today and mounted the coil in front of the tank where the old one was- cannot find what gets plugged onto though. Meaning I’m not sure if its a red wire and if so where that is at? If you had a quick suggestion we would appreciate that. We looked at the diagrams we have but they are not helpful. Thanks for your time.
Payne
Check the ground wire coming off the spark plug coil as well. Sometimes the cheap ground wire breaks coming off of it and it keeps the top end from sparking properly and in sync. That’s a huge problem with these and it’s an easy thing to pass over.
Good Point. I've said in a lot of my videos, when it comes to electrical...Check the ground wires.
Question for you - I have a 2000 Sportsman 500. Just a little history. Back in summer had to replace the starter. Did that but then noticed that the carb was leaking gas. Pulled the carb and rebuilt it put back on and started fine. I then pressure washed it. Might have been a little aggressive with
Thanks Brother, Great video
Thank you sir!
i wonder if you just had a short in your wiring that was fixed by reconnecting/moving wires around. i believe that has a rev limiter circuit that gets engaged only when you hit the throttle, if that was shorted it would kill it the second you touch the throttle.
Thanks I have a Polaris Phoenix had the same problem
My friend, you have to tune the carburetor, look at you spark plug to see if it is running lean or rich, in your case most likely rich. You should adjust the jet by moving the clip in the jet in the carb up a notch, the use the air/fuel screw next to the intake on the carb until it runs fluently. You can also adjust the idle screw as needed because it will need it after changing the air/fuel ratio. Hope this helps!
Another thing to check it the float in the carb. Just found out today while working on a mini atv. Hope this helps!
well it’s not the carb it is sadly an electrical issues, had the same problem with my suzuki vinson 500 yesterday and was trying too fix it, i took the whole carb apart, and cleaned everything, we tuned the carburetor over and over, and nothing changed, we give it throttle and it would die, i’m pretty sure this guy knows what he’s doing if he has a “few motors laying around”, not saying you don’t know your stuff, just saying you can still learn something new, even when you thought you knew everything 👍 i appreciate this guy for the video, i just put in a order for a (OEM cdi unit) and a (OEM Carburetor) i’ll replace the cdi before the carb and i’ll let you know how it goes💯
@@StyFreshhow did it go?
@@StyFreshhey I have a suzuki vinson 500 aswell and I'm having the same problem I'm yet to take the carburetor out but I'd like to hear what was wrong because one of my fuses attached to my battery was blown so I'd like to know how yours went!
@@anyabsentjarl6196 honestly it’s still sitting there not running I was planning on towing it home and working on it I’ll let you know soon! Someone lie my car on fire tonight lol
I got a Artic Cat 300 doing the same thing. Going to look into this.
Well that answers my question dang
I have a 2001 Polaris Sportsman 500 HO, just got it 2 weeks ago its been well taken care of from the previous owner, was doing fine until yesterday. It cranks up just fine put it in forward and goes just fine, when I shift into reverse it just cuts off, I was thinking it could be something electrical too, I find that to be strange, if you have any advice or help I would greatly appreciate it. take care
2004 polaris sportsman 500. it runs great for about 10-15 minutes. Then, it seems like it's suckinv air. it'll sputter and hesitate. Any suggestions?
I just got one of these and I'm troubleshooting. Something driving me nuts. The brown wire from the stator to the ignition coil has a pigtail with female spade connection. I cannot figure where that thing goes. I see in your video it is just kinda hanging out there too. Does this thing go nowhere? Is it Polaris' cruel joke or had you just not gotten around to reconnecting it. If it is the latter, could you please help a poor soul and tell me where it goes? Thanks
Did you ever swap the original cdi box back in to verify?
What’s the tube on the gas tank called bc mine is snapped by the steering bar and I have the same issue with mine
I Have been trying to get an 09 sportsman 400 HO figured out for over a year. Only has 60 hours on it! A dealer serviced it for my friends widow and charged her 1200. Dollars to put a battery in,change oil ,and rebuild carb! They gave it back to her and it still ran like it has water in the gas slash clogged fuel pump! I got it running ok with fuel system cleaner and it wad running nice! Out of no where starts popping,tries to die out. If you put the choke on it'll keep running but badly . An hour later it may run fine and give you no problems for couple days.Always pulls it funny stuff at inopportune times. Took carb apart ,cleaned thoroughly, and machine ran great for a day . Thought it was fixed . Started dying out again on me ! So put new fuel pump on , still running lousy ! I am starting to think electrical . Gonna take the plastic off front and see if any wiring bad under the front deck box on top! It either runs perfect or runs like shut!.Black and white wire from coil and brown wire from coil go up under the front plastic..Maybe a wire corroded or something. If I don't find bad connection ,I think ill change coil.out first than think about control.modules!
Your on the right track. The fuel system is ruled out. One thing to check is the safety shutoff switch by the thumb throttle. If the contacts are close to touching the ride could trip it. If they are touching it will shut off. The reason I say that is after you pull the carb, clean it, put it back together sometimes it gets over looked. especially if the cable was removed from the carb and not re adjusted. Also check the choke adjustment. Just a couple quick checks before you dive into the electrical. But yes electrical would be my next guess. check the plugs by the kill switch too. see if there are any corroded wires there as well.
Hi can you help me i bought a 1996 sportsman 500 but i need to know where the coolant sensor wire goes and where the radiator wires go or come from please help
I have a 2020 doing the same thing. could that cdi box be the cause for that as well. Is there any way i can contact you?
My 07 sportsman efi does this but if I keep the starter in gaged it will take gas an Rev up is this a cdi box? Thanks
Having same problem will after market eBay CDI work or dealer CDI which are over $300
In case someone revisits this thread. Sportsman 400 would die with throttle. I was troubleshooting the fuel pump and placed my finger over the vacuum hose and felt suction. It instantly started idling higher. I adjusted the idling and reassembled the fuel pump and it now runs great. I think covering the vacuum hose with my finger created extra suction in the carb or hoses and unclogged something. I also have an aftermarket carb with a hose cap on the top that was cracked. All fixed.
Hey. Whats the part number for that actual polaris cdi box? Thank you in advance! It's greatly appreciated!
Just wondering if you had a spare computer? I have a 2007 sportsman 500 efi that needs a computer.
Would the exhaust gasket need to be replaced ? My exhaust sounds like it’s going to blow up pushing full throttle and sounds like it’s sputtering backfiring after I let the throttle off. Front header pipes turning blue. It won’t accelerate past 60mph and bogs down, I’m guessing it maybe an exhaust gasket leak in the front? Vstar 650
I would replace it. It sounds like its running lean. Burning hot. Exhaust doughnut could cause that. But also the carb.
Cam, carb, pick up coil, fuel pump, built three 2 had those issues the throttle body plunger also needs to be seated and the air box and hoses need to be hooked up
I posted that in another video. I was trying to keep this one short.
Thanks, for the information. I Have a 2002 Sportsman 500, and Mine will fire up just fine idle ok, but once I let off the gas after per say moving it around it dies or doesn't want to keep running. If I keep my thumb on the throttle it does ok, but this last time I thought I could smell oil, but I didn't see any signs of a leak and the oil level still says full. any tips?
Peel back the throttle cable boot and tighten that up a bit. Should notice a difference. If that doesn't to the trick try adjusting the idle with the set screw on the carb.
Hey there
I have a 2014 sportsman 570 ho that starts at low RPM's and dies sometimes when cold
Low idle RPM's when cold
But idles and runs good after warm up
Only low RPM's when cold
I already cleaned carb. Play with throttle cable and still have the same problem,
What could it be?
You could bump up the idle screw. there air/idle screw at the bottom of carb near the boot. It might have a round plate over it so people don't mess with it. Its usually a turn and a half to two turns out depending on the altitude you live in. You could try that.
What brand cam do you use ? Have a Bigb500 who needs one. //Sweden
I buy used ones within its mechanical limits. there are aftermarket ones out there. but i like polaris brand.
Bad spark plugs can cause the same issue, or a worn spark plug cable the grounds out. Enough spark to idle, but not enough to give it throttle.
I've got a 97 Sportsman 500 that just seems like it's out of time and I've done all of the steps you're supposed to do to make sure that it's in time and replace the cam with an aftermarket. I've got plenty of spark but when I add fuel to it it backfires out of the carburetor. It acts like it's out of time but I've set it twice now and changed the carb trying to trouble shoot, still out of carb. Good spark and motor has low hrs on it, seems crazy to be cdi? It had the idle fall on its face before the no start backfire carb thing. Gonna chk cdi, fingers crossed.
Had that issue on a scrambler. Have you checked they flywheel to make sure the woodruff key didn't snap? That would knock the timing off.
01 Yamaha warrior, does the same do you think it could be the same?
Engine is rebuilt
New carb
Could be possible.
Mine is doing this but it will run with the choke pulled so I’m thinking it’s the carb. Did yours run with the choke on?
Mine does but misses real bad when you give it gas im thinking cdi got new carb still same issue
I am having the same problem. Has been ongoing for more than a year now. I am pulling my hair out on this one. 97 Sportsman 500 that ran great and then slowly started running poorly. After a carb kit, after market carb, adjusting the valves and checking the cam, new fuel pump and china cheap cdi, still does the same thing. Idles fine, but when you pin the throttle it acts like its running lean, backfires and runs like shit or dies. I guess I will try a polaris cdi and see if that fixes it. About ready to junk this thing.
I feel your pain. I went through the same thing with a magnum. Try pulling the black wire on the cdi to see if that makes a difference. Make sure your at top dead center. Check out my latest video..I found a better way to get it there. Did you check your breather hoses for cracks or kinks. One goes to the bottom of the case the other to the oil res. and back to the airbox. One of the big issues..especially with 97 and 98's are too much air getting in and making it backfire. Is the airbox cover warped? If so that will suck in more air and make it run lean. Also check the carb to head boot. I had one that had a hair line crack in it. I didn't see it until I pulled it off. Once I replaced it my problems went away. Hope that helps. Don't give up. Oh..and those Chinese carbs usually only last a year. fyi. Good luck.
I don't know if this will help. I have a 2004 330 polaris magnum and started acting like your polaris. Would idle fine but when you gave it gas it would spit and sputter going forward but when I pushed in the reverse override switch it ran perfect. So I just unplugged the transmission switch plug and now it runs great. Even in reverse there is no need to push in override switch. I believe the transmission switch is bad and telling the machine it was still in reverse when going forward.
@@davidbeeson9594 thats a great tip
I have a 2008 Sportsman 500 HO/EFI machine that does the same thing - idles great - revs up - if I put it in gear and hold down the brake - I can rev it up - but if I release the hand brake and start to move forward - the machine dies immediately. I replaced the voltage regulator and no change. I ordered another ECM module, but it has been on order since last Nov. - 2020!! I am 90% confident that this is my issue, but need to find if there are any used or rebuilt ECM modules for a 2008 machine out there - or if there is a company that can refurbish my ECM module.
There are companies that rebuild them. I can't remember the name. just research them. I'm sure you'll find one.
Hm thanks for the video. I have a can am that has done this since I bought it, same thing except sometimes it just bogs down, other times it dies. Sometimes it does the same thing when the throttle is about to be let go, would it still be that part?
I mainly work on Polaris so I am not certain.
My brake light is not working. Should I remove the crankshaft bearings check the timing and replace the reverse gear cog?
Just kidding, I find your videos very helpful and don’t stop making them please. PS you could always do a voice over for Mike Rowe!
LOL. That's funny.
I just bought an 05 Honda foreman 500 with this same issue. Guy I bought it from put a new carb, new fuel lines, fresh gas. Should I start with the cdi box?
You could try that. I would also check the valve clearance between rocker arms. I had a honda 350. I adjusted rocker arms and it ran better.
@@TitaniummanGarage I would definitely keep that in mind, I will start in the carb and work my way. Thank you
I have the same problem, gonna get a oem cdi box tomorrow
Thanks
Where did you end up buying the new Cdi box from?
I bought a used polaris box. it worked well.
I have an 03 sportsman 700 that's doing the same thing. I changed the cdi and still doing it. Idk what to do next. I've changed carbs, the boot, coil, fuel pump and cdi. It idles perfect, but boggs immediately. You can choke it and it can rev higher. You can block some air flow thru the carb and it'll rev higher.
Have u figured out yet? I have same problem. I'm gonna check the valve lash today to
I have a very similar issue. Starts and idles well. but when throttled past 50% it dies. However, if I baby it past 1/2 throttle very slowly it makes it to full throttle/RPM. I thought fuel pump. replaced, and same problem. Now I think there is something restricting the fuel line. Pulled the tank and found varnish particles. Is there a filter inside the tank? Looks like a grommet there that I do not want to force out and break something.
Yes, There is a filter in there. I blow through the fuel line. Or pull the tank and flush it out.
Did this help? I have the exact same issue. I did replace the fuel pump. The gas fill the fuel filter??@@TitaniummanGarage
Thank you for the reply, I will try the soft magnet, but I think that bolt may be too heavy for such a magnet, and it may even be jammed against the lower Timing Chain sprocket. It is not going to be easy. Thank you anyway.
Franklin
If its by the lower timing chain sprocket, just pull the flywheel and stator cover off. you should be able to get to it from there.
Mine acts like it is hitting a rev limiter at about 1/4 throttle what's your thoughts
What year? 97 to 2001. camshaft. Try a carb clean. check the cdi.
Hello, so far I've liked your videos. I do have a question about a 2005 Polaris sportsman 500 HO that I'm having problems with. I had overheating issues with it at one point which ended up being my plugged radiator but in the meantime it now will start and idle but will not rev up. Do you think you would still be the CDI? That would be the problem? Thank you for your videos
If it was overheating, I would pull the spark plug. See if its wet. Make sure you didn't blow a head gasket.
What is a CDI box, and how/were can I get one. I have a Polaris 850 Sportsman
It tells the coil when to fire and if you have multiple cylinders it tells which one. Check ebay or partzilla.
Tanks x 10000💥💥🤟❤
Did pulling the choke out seem to make any difference when it was running? That’s what mines doing. Idles fine, falls on its face when gas is applied. Pull choke and it will take probably a 1/4 throttle. My guess is a plugged main. Thoughts?
Yup. When you pull the choke it actually allows more gas to flow in.
What if you pull the choke and it dies after a while
Awesome same issue ppl say no way electronic n I also thought cdi all or nothing.... I'll try it
When you give it throttle and it would die did the display also go blank?
Mine didnt have the screen. just a digital speedo.
Hey Titaniumman - thank you for the video and info. I have an 07 Polaris Sportsman 500 EFI that has a similar problem. Starts up fine, idles fine but you have to be gentle to start rolling otherwise it stalls out. It will also bog and feels like not enough fuel is getting to the motor when at 35 mph. Any suggestions or recommendations? - thank you
Did you get this problem figured out? Same issue
@@krisfrench8648 not yet.. I haven't had a chance to get to it. It runs but the stalling and backfires are annoying... But I am planning on rebuilding the fuel pump. You cant buy a new pump alone but there is a rebuilt kit available. I also noticed I was missing 2 of 4 airbox clips, so I will be closing the airbox tightly as soon as they arrive. I dont think it's the issue, but you never know.
@@paulpolanowski9660 did you get your problem fixed, I have the same problem, i had it in the shop (polaris dealer) they replaced wiring plugs going to the tps , iac, and map sensor. then called and said the power distribution box needed to replaced, and that would fix it.. nope it did not. after spending $1200 dollars i still have the same problem .
I’ve got the same problem .. I ordered a new cdi box and it does the same thing .. might be because it’s not an original oem Polaris cdi box . China box
I have a 330 Polaris Magnum, runs almost perfect without the air filter top lid on, as soon as I put the lid on it still idles fine but will not throttle up. Any help would be appreciated!!
I hear that alot with the 500's try adjusting the choke. your not getting enough air.
@@TitaniummanGarage I'll try that thanks 👍
I am having the same issue, but if I put my hand in from of carb it will rev up. Did yours do this? I have had 3 carbs on it also.
Sounds like you have a air leak. I would check the intake boot for cracks.
hey i just had this problem! i put my hand over carb and it finally took and started a little, then i played with the throttle while doing it and it was the etc
Hi I have a question you might be able to answer for me I have a sportsman 400 2x4 2012 I bought as a project it had grabbed a piston I have sorted that but it’s got a few minor problems one is the vent hose is off can you tell what colour the one way valve on fuel tank vent goes on to tank and what and where the tube is routed to and also does it have a filter on the end I would be gratefull if you could help thanks
I'm not positive. But if you check partzilla they have exploded views to show you what you are looking for.
@@TitaniummanGarage thank you for your reply ,I have looked but I haven’t found anything from partzilla but will keep looking thanks again
@@kennethslater9349 let me see what I can find. I'll get back to you.
Before replacing CDI box would the atv idle fine? Soon as you gave it throttle it spit and bog down?
Mine is doing this. I think i might replace the cdi. Ive cleaned the whole fuel system. It sparks but dies with throttle
any update
@@ethanbessel6851
I need help finding where the vacuum lines goes on a Polaris sportsman 500 1998 model. Can somebody please help me? I was so greatly appreciate it!
My 04 sportsman 500 is running rich how to adjust the fuel mixture it’s a aftermarket carb
ua-cam.com/video/cjzIvmUDyZA/v-deo.html Check that one out.
Hey, enjoy your video's. I've got a '96 or 97 425 Magnum 6x6 that's been getting to be a weekly pain in the %&*, just little crap, but all the time. I have a little hobby farm outside Amery and its really needed for plowing and hauling. It's a real work horse. Engine seems fine and starts great, so with the prices of new being so much, I'm considering a frame off resto this summer. Plastic is good just faded, solid frame, most rust is just surface stuff. I figure even if I have to get into the engine, I could probably get another 10 years out of it and it would be worth it. Bring it back to almost new, Paint, new decals, bed liner paint, polish the plastic etc. I'm planning on shocks, cv's, front ball joints and tie rod ends, rear shock, rotors and pads. Rear and front wheel bearings and bushings. Chains and sprockets if needed. Clutch seems to be slipping a bit going up hill while plowing so maybe that also. When I had it into a Polaris shop they test rode it and said the engine felt good. I'm not afraid to throw a couple thousand into it and do all the work my self. After market stuff seems to be all over the place. I was even able to find a new front chain eccentric last year.I bought an owners manual and found the service manual on line, but your video on converting a 425 to a 500 I've book marked! Is it cool to contact you for answers from time to time? You really seem to know these old Magnums.
Thanks. Not sure why some messages are not showing up. I just saw yours now.Thats cool. I like to hear people rebuild them. Around here everyone is parting them out. Soon there will be none left.
Why was your first thought to pull out the camshaft? And then replace the motor? Like those seem like extreme things to do! You should have started with carburetor then CDI box and you would’ve found the problem right away. Always start with the small stuff and then work your way to the big stuff.
Good tip for the viewers. The reason! Because the last 3 500's I had was either a bad cam,chain or timing was off. This 500 the chain timing chain broke. I had just learned the cdi works at idle and not at full speed. That's the message I was passing along. Great comment I suppose to a new viewer it would sound extreme lol.
Hi, do you happen to have a good CDI box that fits a 2003 Polaris Sportsman 500 HO? Would you be interested in selling it to us? I also need two right footwells and 3 rear brake master cylinders. Please let me know if you can help! Thank you for your instructional video.
I don't sell parts. I keep telling my friend I need to promote him. He parts them out. He doesn't want to deal with shipping.
I have a 2005 sportsman 500 HO that is having the same symptoms. However, I think the 2005 has an ECM not CDI, Is this correct? Any suggestions?
Yup. Does the wrench light or fan stay on all the time?
@@TitaniummanGarage no wrench light or fan staying on and it starts and runs with choke on. It Cuts out as soon as you hit the throttle.
james, what did you find out with your machine? I have the same model/year with the exact symptoms.
@@jarodcash601 I wound up using some seafoam clearing up the carb and it’s run great ever since
I have a 2006 EFI that starts and idles but when I give it gas it misses and runs like crap, as the rpm rises it seems to run ok. What is up with that?
Bro mine is doing the same did you ever find out what's wrong?
@@jerryforeman4020
I suspect the throttle position sensor but I don’t know for sure. I need to take it to the shop for service but I have had so many things going on at home like building a decent wood shed and a new steel roof on the chicken house. I need to get it repaired before winter sets in for sure. Trying to set myself up for the coming winter and need my Sportsman to get firewood from the shed to the house..
I will do my best to post up when I find out what is going on.
@@TheSagerider ok thank you sir
@@jerryforeman4020
Hey Jerry!
I went over to the not so local Polaris dealer today and bought a new battery but it didn’t help the throttle issue. I did speak with a service technician and he suggested that it might be the in tank fuel pump but I don’t think it is the pump. It seems to run strong but there might be a crack in the internal fuel line. I will give that a shot tomorrow. I have been a Ducati rider for many years and I have intimate knowledge of fuel tank internal fuel pumps. The tech suggested replacing it but you have to buy a whole new fuel tank to the tune of $750.00, that is not going to happen here. I will keep you informed. :) At least now I can use the thing.
@@TheSagerider ahh okk I have a 2008 Honda rancher and there really isn't a video to help me out so if you can find a problem to the throttle like if you give to much it just shuts off then maybe it's a Honda problem aswell because with the Honda it's already got a new fuel pump and the filter had been clean and you can get it up to speed but again to much throttle it just shuts off and I'm clueless at this point
how much was the real cdi from polaris I have a 2001 sportsman 500 with some similar symptoms like we discussed before thanks again for all your vids
Check partzilla.com
$355
i have a sportmans ho it has spark turn over but it not run like it trying too but no.
I got a 2012, just put a carb on it and the fuel pump thing that’s not actually a pump and it still runs like crap, it idles and starts up awsome but when you give it gas it doesent die but is won’t rev up at all
Maybe you got a bad carb. it sounds like the diaphragm isn't opening correctly. I would take the top cover off the carb and inspect the rubber diaphragm.
@@TitaniummanGarage I thought the old carb was bad so I put a new one on it and it has the same problem so I don’t think it’s the cabr
Have the same problem with my Honda recon 250
Same here trx350. Ran out of fuel at home then filled up a month later fired up and idles fine but wont rev at all.
I'm going to try replacing THE CDI box see if that's my problem. I've replaced the flywheel, regulator, stator, and still doesn't want to rev.
Did you clean the carb?
@@TitaniummanGarage cleaned, rebuilt, replaced.
@@TitaniummanGarage I've replaced the intake manifold, flywheel, spark plug, checked timing and valves.
@@ethanchewning9325 did it work with urs ?
@@MangeurDePoulet idk yet I replaced it and the starter relay went out and now the ignition switch went bad
U got any of it lett
Thank for all the videos i have a 04 sportsman 500 same problem Installed a $ 30 cdi same problem will not rev quick this machine has 780 hours at what hours do you see cam shafts worn , and thanks again
Depends on the year. 97 to 99 had soft camshaft. Around 2500 to most of them being 5000 miles. It's rare to see a 2001 with a bad cam unless something else caused it. Low oil or overheating.
@@TitaniummanGarage thank you very much I'm going to get a polaris $400 cdi box and give that a shot
@@stansimpkins6439 I found one on ebay for 52 bucks made in America. So far I'm happy with it. It's the red box if you look on Ebay.
@@TitaniummanGarage sir once again thanks for taking the time to help me out . Unfortunately I cant find the a red box one that fit a 04 sportsman, the ones i saw have pig tails coming out of it if you a have a seller name or a item# that would be awesome, i did find a couple of used ones , if you have a PayPal account i will compensate you for your time
THANKS
@@stansimpkins6439 Sorry...My bad. I was thinking you had an earlier model. You have what I call the plug and play style. I don't have any. But if you can find a good used one I'd buy it. Check out Powersports nation.
got a dash cluster for a 2011 500 ho sportsman dont know if u will see this but dont hurt to ask
No I don't have one.
The cheap China cdi should have worked, but some are actually and others are DC. There's a guy on UA-cam who shows how to convert any bike to DC then wire it up to the battery. Boom it works every time. I bet you you put a DC with an account current and fried it right away. The ac current coming off the stator is like 50v vs. 12 v DC.
Anyhow, my electric water pump came in last week and this video just got me pumped up enough to go put it in.
Sweet. Thanks for the info. let me know how it turns out.
my sportsman 500 ho ran good then one day it backfired and now wont start now any help would be great
Mine as well
@@trooperlife1 how did you fix it
@@davekeeping2814 still working on it.. haven’t fixed it yet. Do you have spark?
@@trooperlife1 yes
@@trooperlife1 did you fix it?
Where is the CDI box?
The black box under the coil for spark plug.
I'm having the same problem with my 02 500 HO. It's bizarre, some things seem to fix it, put it back together then before long acting up again. It's ripped apart in my garage now. The problem is finding someone who has the same wheeler that will let you try parts. This has been going on almost a year now, very frustrating. Cam is perfect, Aftermarket coil, aftermarket carb. Ran awesome then started acting up
after I parked it!!!!!
Some of the aftermarket stuff makes it worse especially if its made in china.
@@TitaniummanGarage Do you have any adea where the rev limiter is located? In the cdi? or somewhere else?
@@kmisercola7180 Yes that's where the Rev limiter is built into . I am here looking at stuff because I have a guy who is having issues with his & says it hesitates now a few months after he had someone rebuild the carburetor & adjust the valves which he seems to think he set them too tight . He hasn't brought it over yet because I am working on another friend's custom built chopper that needs a new starter so I haven't been able to hear the Polaris run or drive it to see how exactly it's running but from what I hear these Polaris ATVs are known for several problems especially the cams & cranks going bad in them & I also read that Polaris had a big contract with the military for the army if I remember & the army backed out because they were having all kinds of problems with the cams & crank shafts going bad in them & being they need to use a dependable product those issues couldn't be tolerated . I had a 91 Polaris 350L liquid 2 stroke for about 8 years that was used mostly as a work horse on my property & finally sold it but to tell you the truth I would never buy a Polaris ATV again after seeing how mine was designed & how poorly the fit & finish was on things on it plus another friend of mine who had a new Polaris just a year ago & his engine started knocking so he sold it as well & bought a CanAm instead but if it were me I would probably buy a Honda or even the newer Yamaha Grizzly's are pretty well made with not as many issues as these Polaris ATVs seem to be plagued with .
I am working on a 500 sportsman that is stalling upon acceleration. Cam looks good and it idles perfectly. Tried a different carb and cdi with no luck, I also isolated the fuel pump and gravity fed fuel with a gas caddy, still no luck. What I have discovered is this, if you the take the air filter out, and block the intake with a piece of cardboard till it dies, it will start back up and rev up just fine for a second or two. The airbox is jacked up, and only has one screw holding it down. Valves are at spec.
Anyone have any input on this?
Have you checked the throttle safety kill switch? make sure its not touching. And the carb intake boot.
@@TitaniummanGarage yes, I have disconnected the cdi ground per the manual and have visually inspected the boot as well as spray it while running to see any changes.would the vents going to the air box or the one from the carb to the oil tank cause any problems like this?
I have a 2018 850 sportsman I'm going to try this cause my quad just left me stranded on the ice. We have tried everything
The 850 doesn't have a CDI box. I would start with the fuel injection system. What code are you pulling up?
@@TitaniummanGarage it was moisture in the throttle and 4x4 switches
@@bobmackay9281 Interesting! I've had corrosion there but not moisture. I suppose it makes sense.
I put a new carb on my Polaris 425 and found out the new carbs had smaller jets... so it would die once I gave it gas.
I had noticed that too. I usually pull the new jet out ,clean and install old one.
I have a 2001 Sportsman 500 ho. Starts and idles fine. When I ride it, it pretty well tops out at 15 mph, slows down I.der anyoad and starts popping out the exhaust. I changed the carb, and put a new plug in it. No change. I'm hearing that these machines are pretty sensitive to intake air volume. Any known issues with these? Cracked carb boot? I'm about to sell the thing if I cant resolve it. Frustrated.
That's correct. If you have cracks in your breather hoses or airbox it could cause problems. Have you checked your cam and timing? It sounds like a timing issue.
I need a carburetor
My arcticcat 500 is doing the same thing