Hi all, having issues with my 700 twin carbureted model. It recently started missing at a lower rpm but fine at higher rpm... things I have done trying to fix this issue are as follows:
New plugs
New intake
Cleaned carb
airfilter is clean
two new rectifier's "Caltric brand"
Adjust throttle cable
New fuel "93"

After new rectifier it reved up smooth but then would die like I hit the kill switch. So sputtering stopped, but new issue of dying... So I ordered another rectifier thinking I had a bad one, nope same thing.. I am also confused, do I need the new ignition kit?? I feel like I dont since what I read is the ducati ignition is the coil and CDI are one and I have separate units on my bike.

Any help would be appreciated considering I am at my wits end with this and it is deer season....

 

Don't just try to clean a carb rebuild one.Needle and seat wear,jet needle wear are a couple of reasons to rebuild one. Here's the best kit around.Shindy Carburetor Repair Rebuild Kit Sportsman 700 2002 2003 2004 2005 2006 Carb | eBay Plus along with a worn float needle,a float that's not set right can cause problems along with stopped up jets and orifices.Make sure the carb is clean and all orifices blown out.
Here the pdf fuel section from the manual that shows you how to rebuild and adjust your BST34 carb.https://www.google.com/url?sa=t&rct=...U2gGlaHJWSIlbA If rebuilding the carb doesn't completely solve the problem,then you could have a problem in the Kokusan ignition. This 5 buck manual has good trouble shooting guides,electrical resistance specs and schematic diagram that can help track down an electrical problem. 2004 Polaris Sportsman 700 Service Manual PDF Download Plus 93 octane isn't needed unless you have access to ethanol free fuel. 87 is usually fine as the manual calls for.

 

Thanks for chimming in old polaris tech!

I dont feel it is carburetor related since it happened almost instantly when I was riding. Although I wont rule it out either, but I also forgot to mention that the speedo started to act funny as well. Rpms would stick along with the speed then go back to normal. Could this whole issue be the speedo cluster causing this ??

 

Wouldn't think a speedo would cause this off hand,but with electrical problems anything can happen.. Best to download the cheap manual and go through the tests. Has a good section on the speedo itself and trouble shooting steps on it also along with stator tests.

 

So I figured this out that when I put the new Rectifier on "Caltric brand" it will run great but only when the fan kicks on and runs for a minute... Fan turns off and you rev it dies...

 

Problem is on the 2004 there is "build before" date and "build after" that determines which regulator. One isn't too expensive,but the later model is. The generic Caltric sounds like the wrong one for your application. Give a local dealer your vin# and they can give you the build date. Item #24 shows the two different regulators.2004 Polaris A04CH68AK SPORTSMAN 700 (A04CH68AK/AL/AN/AO) Electrical/Taillight | Cycle Parts Warehouse

 

Well Old polaris tech took your suggestion and called dealer to get the build date and was happy to find it was built in 2003. So I ordered up the correct rectifier for that year and got it today. Hooked it all up....rev it up and it dies. Runs great once the fan comes on again but dies when the fan turns off. I feel like when the bike is revved it gets to much current and kills it , but when the fans on it steals some current allowing it to run properly. Hell it runs better without a rectifier... Its bulk trash tomorrow and Im about to push it down to the curb so any suggestions would be appreciated, thanks in advance.

 

If your model is a 2003 and you do for certain have the upgraded Koksan ignition(separate cdi and coil) the regulator listed in the parts break down is still for the original ignition or at least appears to be. There is and upgraded regulator even for it and doesn't say it's for the upgraded ignition kit.. Item #23. 2003 Polaris SPORTSMAN 700 (A03CH68AA/AC/AF/AH/AL) Electrical/Taillight | Cycle Parts Warehouse "IF" you have the old regulator(that supposedly came with the Kokusam kit) look to see what number may be printed on it. This may or may not be the cause of problem you're having. Or let your dealer try to figure this one out.

 

It is a 04 with koksan, build date was 6-23-03. Would the bike shut off if to much voltage is coming through when it is revved? How is it possible that it runs better with out the rectifier?

 

If it runs better without the regulator and you've already tried a couple, then you might be back to a stator problem itself or a short in the wiring harness. One simple stator check is that all the yellow wires have resistance between each other and no yellow shorts to ground. There are more tests than that and that's where the manual I referenced earlier really comes into play with the trouble shooting guides and stator resistance and other electrical checks.2004 Polaris Sportsman 700 Service Manual PDF Download