I just got a 2005 Polaris 600 Sportsman last year from a friend. The second day of riding it, we went up a really difficult trail, but it did amazing. I rode it for the last year, but now I have issues with it just dyeing while we are riding. When it does that, it starts right back up with no problems, but once I give it gas, it bogs down / sputters and dies. We put Sea foam in the gas, and made sure that the gas was fresh. I had a new carb put on it, new spark plugs. The air filter and gas filter are fine. Once I had the new carb and spark pkugs put on, it ran great for about three days of riding, and then it started the same thing again. Once I push on the gas, it bogs down and won't go. Any suggestions of what else to try would be great. Very frustrated right now. Please help.

 

Pull the fuel line from the carb and crank the engine over.Should be a steady stream of fuel if the pump is ok. If it is then could be an electrical break down when it gets hot. On something like this best to have the manual to at least go through the electrical checks and resistance specs to see if this is the problem. Here's a cheap manual for 5 bucks.2005 Polaris Sportsman 600 Service Manual PDF Download

 

I will try that for the fuel pump and see. It doesn't always happen when it gets hot though. it can sit for a day after this happens, and it still bogs out / sputters, and can't go any where. Would that still be the electrical?

 

It can be anything.. Just take it one step at a time,check the fuel flow first. Then check the electrical trouble shooting guides and checks. Process of elimination until you track it down.

 

The fuel tested fine. Looked up recalls on this and it showed that the ECM was recalled. Ordered a new one, replaced the old one. Ran great again for about 2 days, and now back to the same issue. It will run sometimes. When it's in park it idles great. When it gets put into gear, and you go to give it gas, it will either die or if you kinda pump the gas for a little while until it takes, then it will go, but not all the time. My instrument cluster is broke as well. Would this have anything to do with it? I've looked at new ones to replace it, nut holy cow, they aren't cheap.

 

Yes there were recalls on the ecms,most have been replaced. Even replacements can go out again. May or may not be the problem. On the speedo pull the speedo harness connector and see how it does. Plus check the intake manifold under the carb clamp area. 700s were bad on these about cracking and splitting causing problems, didn't sell too many 600s,but manifold is the same. Plus check the gear position switch on the gear case. If damaged or a faulty connection it can limit in forward range. If the speedo is out you can't tell if the gear position switch is working correctly or not.

 

This might be the problem. This is the left spark plug wire. It has been pinched in between the gas tank and frame. I have a new one ordered and it should be here by the end of the week. Let pray this fixes my issue.

 

Had the same thing on either the 2004 or 2005 model 500s that had the same problem from the factory.. Polaris wanted me to pull the coil,but I just replaced the 7mm plug wire..