Hi, I have a 2003 Polaris sportsman 90 for my daughter. Question is, at long run, cple miles on trail wheeler cuts out and backfires, starts back up a few times, goes for half mile does it again. Eventually won't start until it cools back down. Noticed the porcelain resistor under the fender gets extremely hot, burnt my hand when checking wire connection's. This gets hot after a min of just idling, is this resistor my problem? Thanks in advance!

 

Ceramic Resistor will get hot no matter what.. When it dies check that you have spark. If you have spark then check compression. Sounds like many I've seen that will run until it warms up,then dies. Will restart when the cylinder and piston has cooled down. Should be a minimum of 115 psi according to the manual. Plus check the tank vent and that it has good fuel supply to the carb. Could be as simple as vapor locking,starving for air and slowing down fuel until it has time to get another gulp of air in the tank if the vent line is kinked or obstructed.

 

Thank you very much for the info, after checking it over its definitely the spark. But only after higher revolution runs, slower speeds will run all day long and not miss a clip. Mentioned the resistor because it was all I could find that was hot and thought maybe that was it. Thank u so much for the help!! Coil is cool to the touch but maybe that is breaking down?

 

Thank you very much for the info, after checking it over its definitely the spark. But only after higher revolution runs, slower speeds will run all day long and not miss a clip. Mentioned the resistor because it was all I could find that was hot and thought maybe that was it. Thank u so much for the help!! Coil is cool to the touch but maybe that is breaking down?

 

Never had a resistor problem on these. Spark problems because of stators sucking in dirt and water and an occasional cdi, yes. Look over this free manual on stator checks and trouble shooting guides.Plus has other things to check that you may have missed.2003 Polaris Scrambler 50-90 Sportsman 90 Predator 90 Service Manual[1] - Documents