I first noticed it a couple of weeks ago. Unless I run with the choke part way out, it hesitates at low RPM, but runs great at higher RPM. I haven't riden it much until today, this was the first time for the backfires. I'm thinking that it's running lean or the gas is getting old. I can't find any adjustment on the carb except idle speed. I have one month left on the warranty but hate to take it to the dealer if it is something I can fix myself. Any ideas?

 

I had the same problem as you. I put a 40mm 500HO carb on my 700 and it would hesitate when you give it about an 1/8 throttle. It would run good if I had the choke pulled out. I droped the clip on the needle to richen it up runs great now. There is also a mixture screw behind a brass plug on the bottom of the carb that can be adjusted but you have to remove the plug.

 

I had the same problem with 04 600 until I had the cold weather update done,huge difference.The bike started alot better and had lots more power,but still wasn't perfect so I talked with my dealer and he said that they found that putting a pilot jet from a 700 did the trick .I put it in and now only use the choke to get it started.I now can start it and drive it right away without the hesitation 2years of winter frustration gone.

 

Sounds like what I am going through. I just had the carb update installed Friday in my 04.5 SP600 and the bike starts better, warms up faster, and seems to run stronger, but it still has a slight hesitation at partial throttle. When run hard it is not as noticable and WOT is fine, but when opening the throttle gradually there is a slight hesitation. Should I have the dealer put the 700 pilot jet in?

 

Sounds like we all have or had the same problem. I am going to call the dealer tomorrow. By the way, mine never started easily until I accidentally started it cold one day without any choke. It fired right up. It starts right away every time even if it has not been run for awhile. After it starts I choke it to move it out of the garage to warm up.

 

TimV sounds like bad plug.I used to have a to leave the choke on a little bit in order to drive the bike for the first 10 minutes .I would change your plugs and give it try.

 

I just got my first 2004 polaris sportsman 600. The dealer said I would foul sparkplugs before the break-in period was over (10 hrs.) I replaced the plugs at 3.4 Hrs. It has always taken a long time to warm up. I like the idea of getting a cold weather carb. kit. Now it has about 5.0 hrs. It still runs real rough when you come to a stop. Even with the choke off. It seems to be too lean in the early stages of the warm up period, to have to leave the choke on so long. Have anyone else had to replace plugs so often in the break-in period? I'm starting to wonder about this twin.My friend has a 400 and he can start up and in no time, He is off and running. I don't see this thing doing this anytime soon. Or is it just the break-in. I sure hope so, it sure has the power.

 

hey man , i think the problem is much bigger than you all think. I posted a few weeks ago that i had some real bad hesitation problems, backfiring , stalling and all sorts of crap. I brought it to the dealer and they told me the stator was bad. They ordered the part from polaris and when they called polaris about the problem they sent them a huge amount of new parts. Polaris seems to be aware of some machines going out with some bad stuff in them. They replaced the stator , CDI box , ignition coil , and the main wiring harness connecting them all together. It was all covered under warranty thank god! When i picked it up it was about 20 to 25 degrees out all weekend and from the first start i could tell a difference in the way it started and ran. Before i used to have to go crazy with the choke to get it to run. Now it barely takes any choke to keep it running. I would be very careful and make sure your machine gets the proper diagnosis and treatment from the dealer because all those parts would be pretty expensive to replace on your own if not covered under warranty. hope that helps. JC

 

JC, I wonder if they did not also do the carb update. I had mine done last week and it completley solved the problem. I plowed snow several times over the weekend and it runs great. It's single-digit cold here and the machine warmed up quicker and then ran fine without any choke.

I read somwhere that these are set up from the factory to run lean for low emissions. They run OK until the temp drops below around 40 degrees.

 

So Shaft, do you also have an 04 600? I just got the carb update and the machine warms up better and runs better but still has a hesitation at the bottom of the throttle. From 1/4 throttle and up it runs great, including WOT, however, it will only reach 57 mph on black top after given plenty of room to get there, which may be normal, but doesn't seem that impressive for a 600 twin. Is there a bulletin for those ignition parts you listed or is it still a hush, hush situation? Could you help us all out by asking your dealer if there is a bulletin involved? We would all be thankful for any help seeing that you have such an understanding dealer to work with.