I have a 2003 Polaris Ranger 500 4x4 (Non EFI). It starts fine, but seems once its warmed up, it is on the rev limiter all the time/runs like crap. Only seems to do it once it gets hot.
carb has been gone through and cleaned.
would it be an electrical issue?
Do not feel like taking it to a dealer, so if someone could point me in the right direction it would be greatly appreciated!

Thank you

 

Weird year model as parts breakdown jumps from the 99 model to the Series 10 and 11(difference being series 10 didn't have a glove box)then jumps to the 2004 model.. If you have the 3 module set up like this,disconnect the black wire from the limiter module#2 and see if it helps. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Plus when it does this,pull the fuel line from the carb and see if fuel is pumping ok when you turn the engine over. Could be a weak fuel pump.http://www.ebay.com/itm/Polaris-Ranger-400-500-Series-10-11-Fuel-Pump-1999-2012-Replaces-4011545-/191105855210?hash=item2c7ecbeeea&vxp=mtr

 

I will give that a try, and get back to you! Thank you for a response!

 

Still havent tried your suggestion, but i found out by the VIN that the model is a 2004. The polaris dealership i called said there was a service bulletin with a recall on the voltage regulator. Would that cause the problem?

Thanks

 

May or may not be the cause of the problem,but seems all the modules have been updated though. Updated part #s don't always mean somethings faulty,just the # has changed.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse In the case of a service bulletin,that's a different story. 11 years is too long for me to remember all the service bulletins that came through the shop. I's still try to disable the limiter and also check the pump flow.Plus check charging back to the battery at an idle or just above an idle.Should be between 14-14.5 volts if the regulator is still doing it's job. If not, this is the cheapest replacement I've found. Polaris 2204317, ATV Parts Cross-Referencing

 

Old Polaris Tech,
I came across this post in searching the web for the same problem with my Ranger 500 as described by Ogio above. I acquired this unit pretty cheap in basically pieces and have fixed pretty much everything except this and a couple other small items. Its kind of strange the problem won't happen for a couple months and then all of a sudden it will do 2-3 times on a short ride around the property. It will generally work itself out and be fine for awhile. I checked the circuit breaker and mine looked like new, but will probably replace anyway. My unit started acting up last night and I unplugged what I believe is the #2 module you describe above (whole module). It is the only one with a black wire and the problem seemed to go away. I drove for a bit stopped and plugged it back in drove a little it started acting up. Stopped disconnected and drove for about 20 min with it disconnected and it never acted up again. A couple questions: Can the unit be operated long term with the module disconnected? What enables the module? An RPM signal? It appears that the module is no longer available. What would you suggest as a fix?? We only use the unit on our property as a work machine so I'm not too worried about over revving ever.

I realize this post is a few years old but am hoping it gets to you and can offer some tips advice.

Thanks,

Jeff M