A few things I have done today was change out the fuel filter (which seemed clear enough to be able to blow through just fine), and adjust the AWD gap in the right handle bar control. I also used a 5mm wrench to set the idle screw on the carb (tightened it enough to compress the little spring then backed off what I thought to be about 2.5 turns and it runs much better now) and it seems like the choke may actually work now. I will test it in the next couple of days early in the morning when its cold enough to try it out. My plan is to also see if it still dies when it gets hot. My work schedule is definitely getting in the way of my repair time. I just wanna get my new toy out to enjoy it. I didn't expect to be buying a project. Oh well, I'm in it now....I guess it will just take time and lord knows how much money to get to enjoy it (but I will eventually be intimate enough with this machine to know all of it's idiosyncrasies). Thanks for all the help!

 

After putting in a new fuel filter and adjusting the gap in the throttle control (as well as the carb adjustment), the bike runs much better and idles great. After about 5-10 minutes though when it gets hot, in order to put it in High, Low, or Reverse I have to depress the reverse override otherwise it stalls when I give it throttle in gear. I am going to do the rev. override fix either today or tomorrow but I am concerned about one thing. There is an engine temp sensor somewhere. If the engine temp got high, would it have a fail safe to shut the engine down like I am experiencing now? If I do this override, will I be circumventing an engine-blow-up safety put in place by Polaris? Just curious. I think this override may allow me to use the machine until I get a speedo and possibly a sensor.

 

Yes doing the over ride bypasses the speedo limiter. Like one guy that did it,it was just a temporary fix until he could afford to get a speedo.

"Pre 2003 and almost all models that do NOT have the combined override/Speedo function button."

Trace wires from the override button (gray/white & gray/orange) Cut the gray/orange and tape up both ends. Cut the gray/white and tape up the end which goes to the override button. Connect the other end of the gray/white to the red/white (ignition supplied 12v)

 

OPT, thanks again. I am really anxious to get time to work on this and let you know how it goes. As I mentioned, I didn't plan on getting into a project, I just wanted to run the machine and have fun. I look forward to getting it going and getting out. I will post pix of before and after (after I complete the override bypass temp fix) as I have done a couple of small cosmetic things as well. I appreciate ya!

 

OPT,
Well today I went out and completed the bypass override. I let it run for about 5 minutes and then took the bike up the block and back. It used to shut down after getting warm and putting it in gear. After letting it warm up and taking it for a quick ride. I heard the fan kick on so I think its safe to say it was "hot" enough to duplicate the previous problem. Your recommendation worked! (as far as I can tell so far). I am not surprised as you are the expert, I am just very happy that I can now move on to other stuff and finally get out to use it. Thank you so much and I hope karma comes back to you for helping those of us that are clueless. Your help is greatly appreciated and you are a HUGE asset to the forum. Thanks again and stay safe!

- NobleEagle

 

Glad you're up and running. I've been clueless many times,according to my wife of 44 years I still am.. Good luck.

 

Oh boy ,you can believe I'm saving all of this tricks for when my time comes"Knocking on wood". LOL

Awesome.

 

TLC, I have done the same with a number of things and it seems as though people on this site are happy to help if they can. OPT has saved me (and I'm sure many others) loads of time and money. I just hope he realizes how thankful I am. After I get out for a test run which I hope to be soon, I hope to find some people on here that are in Florida that I can ride with. Good luck to you and be safe.