Interesting. I have this same problem on my 06 450. It's very unpredictable. I have heard that by adjusting the idle that it might go away, but I haven't tried it. I have no idea when it is going to happen either. I couldn't make it do it for my life. Just out of nowhere. We will be backing up on a trail and she will just stall out. Doesn't matter if it has been riden for a while and is nice and warmed up or cold. I do know this is my last choke based machine. It will be EFI from here out.

 

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From all I've read above, I would probably look next for a wire that's intermittenly shorting out or not making full contact. This could be anything from a ground that's got dirt in it, to a wire that's broken internally. You can sometimes find the broken wire by wiggling each wire down its full length while the engine is running and listen for a hesitation. The grounds need to be disconnected and cleaned.

GJRonK

 

if you know anyone else with a similar machine, try swaping them CDI's and see if that helps. I know for a fact that Polaris has a recal on a lot of them, your dealer should be able to tell you if your machine qualifies with the machine serial # but since they arent always correct, I suggest swapping it with a good one and see if it helps your machine and produces the same problems on the other machine you swap it with. Both my 04.5 500 and my wifes (my back up machine LOL) 04.5 400 have had to have the CDI's replaced for various things, and not both the same problems.

 

Just curious if anybody found a solution to the problem. I haven't been riding much since I last posted, but had to do some recently to do some snow plowing. And now the frequency of the problem is really increasing big time. I'm going to have to take it in I think. What I did notice though....was when it would stall I could turn it over repeatedly and get nowhere (it's not starting right up like it was). So I'm getting ready to do some kind of Indian rain dance to get it to go again...and I decide just for grins to turn the handle bars just slightly and it fires right up.

So... a few moments later it died again. I did the same thing...turned the handle bars just slightly and it fired back up again. To me, which I'm not very mechanical, it sounds like something is pinched. Just curious if any of you are having the same problem and if you try turning a bit if yours fires right up also.

 

I haven't driven mine much either since I went through everything but from what I did I don't think the float was the problem, the one thing that was out of adjustment was the freeplay on the throttle cable. When I peeled the boot back to expose the adjusting screw, the lock nut was backed off and the freeplay was off, it took several adjustments to get it down to factory specs, I noticed too that doing it with the engine running vs. off made a differerence in the setting. I'm pretty confident that this was my problem but if you are noticing it cutting out when you turn the bars you might have a pinch/ground out going on too.

 

Interestingly, it's not cutting out when the bars are turned. It does it when they are straight. When I turn is when I can get it to start again. Which in theory, makes me think there is too much slack in some cable or something. When I turn, perhaps that takes the slack out. I'm grasping at straws of course.

Once I let off the throttle...like to shift in to reverse is when it dies. Or if for example, shifting from low to high from a stop. The initial start is no problem. It's once I get going she dies. I got the flashing wrench, so it's time to take it in for service anyway. The frustrating part is doing this while plowing. Which of course, you have to shift around all the time and stop and start.

Overall, I'd say after having the 450 for almost a year now I'm not real impressed. I'd trade her in, but it's paid for so I'll most likely just post on here whining from time to time [img]i/expressions/face-icon-small-smile.gif[/img]

 

I haven't figured out my problem yet either, although I haven't ridden much in the past few weeks. I did ride last weekend some with no problems so I don't don't know what to think. I was hoping someone here would find the magical cure for me! It must be something small like a loose ground or faulty wire that will be very hard to identify.

 

800 twin EFI....Sorry to here about your problems....How many hours do you have on your 450? I have two of them...My has around 950 miles and my wife's has about 600 miles....No problems YET!!! You said your reached the 50 hour service...Do you have the glacier II plow system....How do you like it with the 450.....Thanks...........caper.........

 

My 04 ATP 500 did the same thing new and what I found on mine was the throttle cable would work its way into the pod assembly when riding.Then when the engine idled down WITH the bars turned to the right,engine would die.ETC was activating.I pulled some slack outta the pod and taped it to the bars,set the idle and all is well now.Between that and a pinched wire harness to the front diff causing no 4by4 discovered on my first ride I was a little irate at my dealer for lack of dealer prep.A 2 hour drive was not an option to the shop so here's me working on my brand new 4 wheeler on its first day home and the wife says I thought you bought a new one so you didn't have to work on the old one.Real funny.