Hello everyone, I have a 95 Polaris Sportsman 4x4 that is having serious problems.

If you start it cold, it will run like a bat of hell, everything works great. After you stop however, you can't re-start it with the starter. You can only get it to start with the pull cord. Once you get it to start though, it will run terribly. It runs very rough, almost like bogging down, but different somehow.

I went to the local Polaris dealer and explained the problem. They said that I had water in the fuel. I drained the tank, replaced all the fuel lines, replaced the fuel filter, cleaned the fuel pump, and dissassembled and cleaned and went through the carb. Could not find any visible problems...everything looked right. Drained the tank and started with new fuel...same problem. Finally, we bypassed the fuel system completely and got gas straight into the carb...same problem. I can honestly say that we have ruled out the fuel completely.

I checked spark, which was just fine. We then checked the speed limiter, which also appears fine. There is something wierd with the reverse sensor, it has never worked and we discovered that it has been disconnected for some time. When we reconnect it and hook up the reverse light, it kills the engine when put in reverse. We bypassed this system and still have the same problem. Thinking that maybe something was wrong with the speed limiter, we bypassed it....surprise, we still have the same problem!

I am at a loss as to what could possibly be wrong with this thing. Everything looks just fine. It appears to be an electronic issue of some kind, but I haven't ruled out mechanical either. Anybody have any ideas?

 

Try by-passing the etc. This is the Electronic Throttle Control that is housed in the throttle housing. When the throttle is adjusted correctly, the contacts should not be touching each other. This may not be the problem at all, but is worth looking at. I have a hard time believing that an electrical problem will worsen as the engine warms, but could happen I guess. I would suspect a fuel, fire, or air issue. Also could be worn engine parts.

 

The only thing I've ever had break down under heat is a coil. It will stop and not restart till it cools down

 

First off check the engine compresion has to be at least 115psi .For the reverse problem follow the BLACK wire from the reverse over ride box and unplug it from the wire box.