I went for a ride today and the 800 Sportsman run fine after about an hour of running I was sitting in my driveway with the atv off and entered diagnostic mode to set the clock when I started it back up I had a loud pop right under the seat and it shut off when I finally got it started back it was running very rough with a lot less power and popping like backfiring. What did I do? also when it gets hot the starter just spins without the Bendix engaging and then it will catch and start, is my starter going out?


2009 Polaris 800 EFI Sportsman

 

Check the wiring from the tps and tbap connectors for any bare spots or soft feeling wires that may have melted internally.Also pins can pull back a little in the connectors and cause problems. Codes may or may not be thrown.Same for the cps sensor harness that runs from the stator under the throttle body. All it takes is a bare wire touching metal to screw things up. If you find a harness problem,this place has better repair kits than Polaris. https://otbpowersports.com/products/ Make sure the battery is up to snuff and not ready to be replaced. Charge it up and do a load test with simple meter.https://www.batterystuff.com/blog/ho...ry-is-bad.html That may or may no have anything to do with the starter or bendix,but you can at least eliminate the battery. If you get down to starter problems DB electric has some good prices on both. https://www.dbelectrical.com/starter...ris/sportsman/

 

I checked the wiring and did not find any bare wires and the ecu is not throwing any codes. I do know when I heard the first loud pop it was not engine backfire and I smelled something like electrical burning. It will start with giving it some throttle but runs very rough and will not idle. Any other ideas as to what to check before going to the dealer so they can hook up the computer and figure it out?
Thanks OPT for all of the help that you provide to me and others.

 

Sometimes a good dealer can actually save you time,money and frustration.This sounds like one of those times.Using a meter in your garage can only go so far on efi systems. Digital Wrench should be able to catch it or at least narrow down the problem area.If they do happen to come up with it needing a harness repair kit don't let them install the crappy ones Polaris sells. Same thin wiring,same cheap connectors.Remember otb.https://otbpowersports.com/products/