Ok guys you were dead on and helpful with my last issue, here is another. 05' Sportsman 800 efi. When its been running for a long while like in the woods at slow speeds it will start skipping and then it just wants to quit and eventually will quit. I believe it has to do with it getting hot and something is not compensating. When it starts to skip and shortly before it shuts down, I start to smell fuel. I think that smell comes from the breather that goes back into the air box.
The other question is that the book says that you are supposed to turn off the kill switch and leave the key on and the fan will run until cool enough and then it will kill all the power. All I can do at this point is leave the key on and hope to remember to come back before the battery dies. If this is true and the kill switch is supposed to do the job than this tells me there is a relay somewhere. Anybody know where? It sounds like this is a twofold problem but they both related to heat. Anyone else had heating issues with these monsters?
Thanks
bullbro

 

i have heard that it could have something to do with the fuel pump over heating when the fuel gets low. since the fuel pump is in the tank and is normally submerged in fuel it runs normal until fuel level gets low and the fuel pump overheats and causes engine to sputter and die. and yes i have had simiilar problem on my 06 800 sportsman when on a few long rides. except i never smelled fuel like you said... after inspecting all connections hoses fuses etc etc the bike would start and run normal..maybe because it cooled down? its still a mystery as to what the problem was for sure.. but the overheating fuel pump sounded logical to me. because whenever it happened the bike was hot on long ride

 

get the new pump in and then see if its still doing it.

 

Well did the pump fix it?