Firstly, I'd like to say, this is my first post. From what I've read this seems to be a great forum! Hopefully I'll learn a lot here!
Now, on to my questions!

'03 Sportsman 600 Twin
I bought this machine last fall, and I've been having problems with it since. I know its a good machine, but it hasn't run worth a darn since I've purchased it and I'm getting discouraged. I believe this is the re-jetting issue, but here are my problems. Firstly, it started running really bad after about 2 weeks. Backfiring, not idling properly etc. I had to run the machine at about 1/4 choke to even keep it running. The plugs were fouled. Replaced the plugs, and it ran like a raped-ape for about 20 minutes. Then as I was riding I noticed when I hit about 35mph, and pushed the throttle past 3/4-full, the machine would bog down, and actually slow down. Even if I let the machine warm up for a long time, I still have the problem.

Question 2
'04 Sportsman 500 H.O.
This is my buddies machine. He rode it for the 3rd time yesterday. What happens is the machine starts fine, idles fine. We were riding straight up a logging road at about 25MPH and the machine cut off. Stopped dead. Tried to restart - it turned over 3 or 4 times, then started spitting and sputtering, back fired a couple times, then took off. This happened again 4 more times about every 50-100 yards. After the first cut-off, in order to start the machine again, the throttle had to be held in about 1/8". Needless to say, he was less than excited about his new problem. We don't know where to start. We called the dealer, he said "He needs to drive it a little more". I say BS. There is definitely something wrong. It shouldn't shut down, with a steadily held throttle going in a straight line. Any Ideas?

Bo

 

well there is a breakin period ware you shouldent hold the throdle steady, first 10h, you should be reving it up and down and best to do that on the trail's. but i still here you, it should not just cut right out like that. I have a 2002 400 sportsman, never had any problem like that, well it didn't idle there for a while, but that was afer drowning it in water and it was floting, and tanks to the air filtter being high under the gas tank no watter in the card, but there was a hose clamp missing on the belt-drive vent and a bolt lose in the cover so a bit of watter got in the belt, but that was dryed out pretty fast.

 

Here is something to try
Polaris, Sportsman 600/700 Air box Tip

You are eventually going to open your air box to check the filter. This will save you some aggravation.



There is a small, clear vinyl carb vent tube that is clipped to the CVT snorkel. This tube needs to breath freely. It is curved downward and is very easy to get the end of this tube into the air box snorkel when replacing the air box cover. Just a little something to keep a lookout for.



Symptoms are: Idles well, but when you hit the throttle it bogs, back fires and wants to die.

 

Hi, with your bike I would pull the air filter box top and remove the filter and ride it a bit. Sounds like it need more air. Could be a wet filter or a blockage in the inlet tube. I have seen dirt-daubers build a nest in them thing and they are hard to see. I had a bike that belonged to my father-in-law that did the same thing and it was a nest in the inlet tube. Let us know what you find. Good luck. Charles

 

Well we got the problems solved.

On the Sportsman 500, during assembly, the carb vacuum hose got pinched between the frame and the gas tank (quite badly). Machine wasn't getting enough air.

Sportsman 600 - A small pine needle somehow got into the carb and was blocking one of the air jets causing all sorts of problems!

If anyone has any ideas how the pine needle may have gotten in there, I'm interested in hearing them...

Bo

 

Just a guess, but probably through the carb vent line. If not, then maybe your dealer or the assembly line... but that's kind of hard to believe.