Got a brand new '06 Sportsman 500 EFI on Wed. Worked great Wed thru today. While trail riding today, I came to a stop, and the machine just died. Wouldn't start. After just trying different things, I was able to start while giving it gas in order to get home. Any time I let all the way off the throttle, it dies -- as long as I have the throttle the slightest bit open (with this my thumb slightly moving away from the resting point) it runs/idles fine.

So I popped the cap off the top of the AWD/throttle box. I see there is a spring inside that pushes these two contacts together. When you open up the throttle, it separates those, then starts pulling against the throttle cable. When you let all the way off, as soon as it touches those two contacts together, it dies.

What do those contacts do? What is broken that when they touch, it dies?

Help please....Thanks all.[img]i/expressions/face-icon-small-sad.gif[/img]

 

Hello cmatt. Believe it or not, it is supposed to do that. What you want to do is find the throttle cable adjustment screw which is on the throttle cable about 10-12 inches below the throttle housing. Under the rubber boots are the adjustment screws for taking the slack out of the throttle cable. Adjust the cable by tightening the screws until there is about a 1/16" between the two contacts in the throttle housing. This should solve your problem. They probably put this into their quads to make sure there is no slack in the throttle line. Not entirely sure. Happened to my son's ATP 500 HO. Hope this helps you.[img]i/expressions/face-icon-small-cool.gif[/img]

 

its suppose to do this to override a full throttle (like a frozen full open). it needs the slack to work right. most likely the dealer didnt do a good check list when putting this bike into service.

 

Do you screw that piece all the way down, or reverse all the way up? I did that, but there is still slack enough for those to touch.

I read the book, and it references Electronic Throttle Control for if the throttle "freezes or sticks"... when you let off, it kills it. I guess that is what is happening here.

How can I tighten more?

Thanks again.

 

thats what its doing alright. the throttle should have a little slack in it when you push it. its the adjustment in the cable to loosen it.

 

You want to turn it whatever direction will tighten the line. I'm not sure what direction it is. Have someone watch the contacts while you go in one direction. If they stay in contact go the other direction until you have about a 16th of an inch.

 

That fixed it!!! Thank you very much. Big scare for a minor adjustment.

Back in business. I really appreciate you all responding quickly.

Take care.

CM

 

I had the same thing happen to my 500 EFI due to the cable being slightly out of adjustment to begin with, then after a couple rides, it was stall city. Messed with my mind for a couple hours, but figured it out.

 

That is the truth...mind went from loving life to major frustration in about 1 min.

We rode again today, and it did awesome on some pretty rough trails where we had to do some rock crawling. Low range is awesome.

I really like this machine.

Thanks!