Alright guys I'm still having problems. I think I know what part of them are. First off, I have a 700 polaris sportsman 2002. I took it out saturday to till up some food plots. I shut it off after tilling and it seemed pretty hot, but it wouldn't start back up. 15 min later it started up fine like nothing happened but I had to let it cool off. When it starts it sounds normal until it gets warm. I'm now thinking vapor lock? How do I prevent this? Do I get some heat tape and go over the gas lines and around the gas tank to send the heat more out the back. I thought it was the coil pack but have since ruled that out. Anyone have any input on that? Next and probably the bigger problem. I had a lot of problems earlier with bogging and had gas in the crankcase. I replaced the carb boot, air filter, fuel filter, plugs, cleaned the carb multiple times, changed the needle, seat and float also changed the oil and filter along with 1 spark plug boot. The bogging problem seems to have been fixed well for a while. Now after all that it ran really well for about 40 miles. Now I checked the oil everytime I started it and there is gas in the crankcase again after this weekend!!! and it boggs off and on but not very much. I haven't drove it since the gas in oil problem but I don't know where to go from here!!! This is turning into a nightmare. I know its not good but I don't always remember to shut the gas off after riding. This shouldn't be the sole problem for this should it? What am I missing with these problems? Help anyone??? lol Thanks

 

did you check the air vents on the handle bars for the tank and carb to make sure there not blocked/pinched? is the fan running. rad. clean on both sides. you said it gets real hot, is it overheating?

 

Sounds like you have covered the carb,fuel and some other problem areas,but you say you have ruled out the coil pack? Do you have the resistance specs on the coil pack and also the stator? You might want to check the specs whens its hot or acts up. Coil packs are still available,BUT if stator specs turn out to be low or bad,then stator supercedes to a new system entirely! Includes stator,flywheel,CDI unit and separate coil! I had this problem several weeks ago. where the coil pack showed bad and I DIDNT check the stator and had to replace the entire electrical system! I dont know if this is your problem or not ,but on ALL owners of early 700's I try to warn them if they just replace the coil pack and the stator is the problem,dealers WONT take the coil pack back. New electrical system over $400, coil pack a little over $200. Like I said,dont know if this is related to your problem,but good info to keep in mind! Only other thing I can think of if you have gas accumulating in oil,air box,etc is to check vacuum line on fuel pump(should be dry leading to carb,if wet then pump may be need to be rebuilt or replaced) ???? OPT

 

Is it the snorkel that comes up from the carb? If that's what your asking, then that is clear, I know I checked that. The tank vent..where would that be located don't think I checked that. The fan runs everytime after 15 minutes of straight riding or little less if dragging a disk or pulling a trailer, the person I bought it from had heat tape that was on the plastic outer panels that I took off and this is the first time I actually felt the heat. Maybe it normally gets that hot, I guess I hadn't felt that before. But I didn't re install the tape. Maybe he installed it because he had a problem with it before. I remember he said something about the tape but I can't recall anymore. Haven't had time to check the rad. but I should be able to see through it correct? I need to remove the front rack and look inside the hood so to speak.

 

Well I guess I shouldn't say I ruled it out but I have even spark on both sides taken between the coil and the plugs. I know how to change the coil....had that off already..lol I don't really have the tools to check that or the stator so if that might be the problem its probably going to have to go in to the shop for that but I can check the fuel pump and the other things listed above. Only other thing is I've noticed a smell, that at first I thought was exhaust but the more problems I have the more I think it might be an electrical smell could that be possible? Its getting to the point with the luck I've had lately where I hear a noise or a different smell and immediatly think something's wrong. I think I need to just step away from it for a while then come back to it. Any other recommendations on checking would be great, I'll probably look at it Friday or Saturday. Thanks!