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2008 sportsman 500 h.o efi runs bad

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Old Jan 15, 2016 | 09:00 PM
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Default 2008 sportsman 500 h.o efi runs bad

I got this as a trade for a sled I paid 600 bucks for so I'm thinking I'm doing pretty good but there's a few issues. The throttle is frozen or something (its been very cold here recently ) I took off the cover from the throttle on the engine and noticed its very rusted and had ice in it but turns just fine, the thumb part just doesn't move. Also its throwing a few codes, 12, 22, 45, 47, 58, 55, 74(checked and rechecked this), and 61 quad starts and idles but dies out sometimes seems rough when I rev it
 
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Old Jan 16, 2016 | 03:17 AM
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I'd either look on ebay for a throttle assy if it's rusted or even here. Little over 100 bucks for a new one complete with etc switch and awd. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Some codes throw are bogus,but most times when code 45 is thrown it's a problem on the tbap wiring harness or connector. Read the "sticky" post above this section on efi problems. Links to a place that has better aftermarket harness repair kits than the oem crappy ones I had to install that kept failing. Only The Best
 
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Old Jan 16, 2016 | 02:37 PM
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Originally Posted by old polaris tech
I'd either look on ebay for a throttle assy if it's rusted or even here. Little over 100 bucks for a new one complete with etc switch and awd. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Some codes throw are bogus,but most times when code 45 is thrown it's a problem on the tbap wiring harness or connector. Read the "sticky" post above this section on efi problems. Links to a place that has better aftermarket harness repair kits than the oem crappy ones I had to install that kept failing. Only The Best
I was looking at those yesterday but was worried maybe I have some other problems. An entire wiring harness is cheapish, might that be a better route? Or is there any way to pull the pins from the stock connector and replace the wires myself? My plan was to pull the entire harness today and do a continuity test on every wire but its -22 today and I've never pulled a harness from one of these quads before
 
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Old Jan 16, 2016 | 03:00 PM
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Originally Posted by newtonty
I was looking at those yesterday but was worried maybe I have some other problems. An entire wiring harness is cheapish, might that be a better route? Or is there any way to pull the pins from the stock connector and replace the wires myself? My plan was to pull the entire harness today and do a continuity test on every wire but its -22 today and I've never pulled a harness from one of these quads before
You can check pins and wires if you wish,plus look for any bare wires or soft feeling wires that may have melted internally. The complete harness comes with the SAME thin crappy connectors and thin wiring to the sensors! That's why I mentioned the other site. Only The Best I replaced more oem Polaris harness repair kits than I ever want to think about.. Multiple times on the same vehicles also when the first kits I installed failed again. That's what the "sticky" post section above on efi problems is all about. The thin wiring and crappy connectors.
 
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Old Jan 16, 2016 | 03:04 PM
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Originally Posted by old polaris tech
You can check pins and wires if you wish,plus look for any bare wires or soft feeling wires that may have melted internally. The complete harness comes with the SAME thin crappy connectors and thin wiring to the sensors! That's why I mentioned the other site. Only The Best I replaced more oem Polaris harness repair kits than I ever want to think about.. Multiple times on the same vehicles also when the first kits I installed failed again. That's what the "sticky" post section above on efi problems is all about. The thin wiring and crappy connectors.
I've read a lot about the crappy connectors but when I checked yesterday everything seemed good. But I've read that it breaks under the insulation. I think I'll buy the 3 pack of connectors I just feel its a little steep (I'm from Canada so each connector comes to around 90 dollars and 200 for the 3 pack) but hey if I can have this thing running smooth for 200 bucks that's 800 dollars all out for a running 500
 
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Old Jan 16, 2016 | 03:09 PM
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Originally Posted by newtonty
I've read a lot about the crappy connectors but when I checked yesterday everything seemed good. But I've read that it breaks under the insulation. I think I'll buy the 3 pack of connectors I just feel its a little steep (I'm from Canada so each connector comes to around 90 dollars and 200 for the 3 pack) but hey if I can have this thing running smooth for 200 bucks that's 800 dollars all out for a running 500
The guy that sold it to me also told me that when he unplugged something it ran better and he was able to ride it I'm guessing he unplugged the map sensor
 
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Old Jan 16, 2016 | 03:09 PM
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You're looking at the wrong thing! Not necessary to buy all three! Just the pressure sensor repair kit that triggers code code 45! That's the main one that fails.. This one for 39.95.
 
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