The problem sure seems r.p.m. related. If you are going 35 m.p.h. and ease into the throttle it will start missing. Playing with the throttle at this time will yield results and it will run on up to about 57 m.p.h. top end. Now, if you are going 10 m.p.h. and mash throttle to full the engine may miss once or twice but will get through the dead spot much quicker than the 35 m.p.h. scenerio.

Yesterday I cleaned the carb, paying special attention to the diaphram and needle slide. I removed the plastic slide rail to clean it better and I saw a wear line on each rail of the slide. The lines were about an inch from the top of the slide. The wear lines were formed in a manner that looks like any binding would occur only when the needle slide is trying to move downward. After I reassembled the carb, the needle slide feels silky smooth as you move it by hand.

Today I disconnected the black wire from the C.D.I. module and the problem still persisted. I have read about the cam shaft issues on this model but my gut says that is not the problem. I never hear a backfire. It just really sounds and feels like a fuel starvation issue to me. The needle clip is in slot 3 and the pilot jet is 2 1/2 turns out. This is a stock machine.... no mods.

Any suggestions greatly appreciated.

 

Black wire from the cdi or reverse limiter module? Sometimes just cleaning carbs doesn't always help. A worn float needle,needle jet,jet needle can cause problems. I'd always install a carb kit to eliminate any possibility it's a carb related problem along with checking the intake manifold for any air leaks. Plus you can pull the fuel line from the carb and crank the engine over to see if you have a steady flow of fuel from the fuel pump with the fuel valve in both the on and reserve position. Fuel valves can be faulty also.Being it's still a 99 model I'd still measure the exhaust lobe. If you don't have a manual here's one that gives the cam specs along with trouble shooting help on fuel,electrical related tests. http://gh-ftp.com/ORV%20Manuals/Pola...0%20-%20SM.pdf

 

It was probably the reverse limiter module, it had eight wires coming out of it and with the black one disconnected from the harness, the engine will not shut off.

Crap ! I really don't want to deal with a flat cam lobe. I just can't imagine how it can make enough power to run 57 m.p.h. with a flat lobe ??

Any leads on where to get the carb kit ?

 

If the engine won't shut off you pulled the kill wire from the cdi,not the limiter. May not be cam related,BUT the manual can keep you from chasing your tail as you eliminate one thing at a time.. Carb kits are available all over ebay among other places.http://www.ebay.com/itm/NEW-SHINDY-C...792a74&vxp=mtr

 

I have the O.E.M. Polaris service manual but am going to look at the one at the link you provided also.

How do I disable the rev limiter so as to rule that out ?

Thanks kindly for your time.

 

Just pull the black wire from the reverse limiter and hook the black wire back up from the cdi..