Intermittent problems are usually electrical. I'd check all connections (easy ones 1st, like battery cables), and check out the coil to make sure all wires are properly plugged in ans secure.

 

my 03 700 also went back to the shop for a bad stator....every oncwe in a while it would just quit like the key was shut off....then it would start again....one time it wouldn't start......dealer time...

 

700rider
The Pilot Jet # 27 must be removed to be cleaned and inspected. I must of had this carb apart 5 or 6 times till I found that speck of dirt. As I said before the pilot jet is like a dirt trap. A small particle of dirt can be sucked into the inlet side and can't get out, yet is too big to get pulled through the outlet side. So it bounces around in the jet till it gets stuck and causes a lean condition. Then it would drop down and run normal again. I also had a similar problem on my 700 and found the intake manifold boot cracked due to a poorly designed carburetor bracket. In 04 Polaris switched to a much better bracket.
I do feel your problem is fuel related and not electrical because pulling the choke out a little would not improve a problem caused by a faulty electrical connection.
Now that I have a pair of EFI's I will never go back to the carbed versions.
Keep us posted on how you make out and good luck,
Paul

 

Thanks again for all of your time sharing some ideas. I dread taking that carb off again, but feel it must be done. I will thoroughly check the pilot jet along with the intake boot. I agree as well with the poor design on the carb bracket. Regards.

 

Check the manifold for cracks. As mine is made of rubber and the bolts supporting the carb fell out the manifold craked and was sucking air. I had to run the choke on part way and never noticed the crack til I got home. covered it with caulking to see if that was only problem and it cleared up immediately.

PS where can I go to get a new manifold besides the dealer?

Any Ideas???

 

 

[img]i/expressions/face-icon-small-frown.gif[/img]I've had the same problem with my '03 600 twice now. Both times, I sucked up a pine needle in my jet. The last time, the dealer installed a one-way checkvalve on the carb breather tube, no problems since. It can sure ruin a good ride plus $50.00 labor!