The something small and stupid is the thin sensor harness wiring I still believe. Even a new harness has the same thin wiring that won't hold up to voltage or vibration. I replaced I don't know how many cheap Polaris t-bap and map sensor harness kits that had the same thin wiring,only to have them fail again! The OTB harness is 39 bucks and from all reports solved many of the problems people had. I just wish I had these when I replaced all those kits. I wouldn't have had to replace some 2 or 3 times later with the same sorry wiring kits. Plus read the "sticky" post above this section if you haven't already about the efi wiring problems as it goes into details about this. Only The Best

 

I will remove the entire harness and go through wire by wire, and also replace the map sensor harness. I will post the results, I hope you are right.

 

.....wow,what a story,would love to know how it ends

 

The map sensor repair had no success, I also removed the muffler and tried that, did not help.

 

Think you have a lemon if there ever was one: being a used machine and originally tampered with,new wiring harness,various sensor replacements,new throttle body to replace the one tampered with,new harness kit(OTB I hope) two dealerships hooked up to Digital Wrench and still can't find the problem on not idling? The only thing I could think of is something mechanical and not electrical. If you've eliminated anything mechanical also,then you might give a third dealer a try to see if the others have overlooked anything at all. If that fails,then I'd part this sucker out as one dealer suggested and cut you losses and move on!

 

If you think mechanical, what do you suggest I try?

It has actually been to Three dealers, the first did all the original work (ECU, harness, stator, etc) the middle did a diagnosis, found no faults. The third is the most recent, rechecked everything I did and the previous dealers, that is also when Polaris has gotten involved.

I would just hate to have to part this machine out. It is in really good condition, low hours and was taken care of.

Would just like to thank you for all the assistance provided. It is appreciated.

 

Just what did you show when you checked compression when you checked the cam shaft and valves out,plus has anyone performed a leak down on this machine to eliminate any valve leakage or any other leak that would affect it at an idle?

 

The last dealer completed both (to verify my results) compression and leak down were both completed, they said it was near perfect. The valves were also checked using the solvent test. Then the concern was incorrect camshaft (never replaced) so it was removed and inspected to verify no wear and proper grinds. Timing was also inspected.

 

So the head was removed to do the solvent test and replaced I assume?

 

I am unsure, in the list they provided me of their conversations with Polaris, it just said it was solvent tested. I know I did the solvent test, but only on the intake valves.

If it would help, I could copy the list that the dealer gave me and uploaded it.