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2004.5 Sportsman 500 H.O. wont start unless intake is covered :(

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Old May 2, 2012 | 02:41 PM
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Default 2004.5 Sportsman 500 H.O. wont start unless intake is covered :(

Hi there, i was having problems with my sportsman where it would only start for a few seconds on full choke or with the air intake covered by my hand so i figured if i rebuilt the carb i would be set. That didnt work and in the process i added a new spark plug, in line fuel filter, and air filter. Still wont start unless i cover the intake with my hand, any suggestions? Thanks!
 
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Old May 2, 2012 | 03:25 PM
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Has it had the ECM recall done?
 
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Old May 2, 2012 | 03:33 PM
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I dont believe it has, all the electronics still seem to work right, would it still cause the atv not to run?
 
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Old May 2, 2012 | 05:47 PM
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dont know much bout the polaris but sounds like its sucking air or a air/fuel mix problem
id start by
1. check for leak around intake/carb (get er runnin and spray some starting fluid on it and see if it revs up)
2)tweak the idle air screw?

or make sure u have the float adjusted properly
 
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Old May 3, 2012 | 09:09 AM
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If you have to choke it off to get it to run at all, then you have a massive vacuum leak.

Fred
 
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Old May 3, 2012 | 09:21 AM
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nevermind
 
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Old May 3, 2012 | 10:24 AM
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Originally Posted by Sportsman500H.O.2005
I dont believe it has, all the electronics still seem to work right, would it still cause the atv not to run?
Like TLC mentioned if the ecm hasn't been changed all sorts of problems can happen. From no charging to just killing it and they won't restart and anything in between. Have this module replaced first if you still have the old "black finned Chinese module" OPT
 
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Old May 4, 2012 | 11:28 AM
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Thanks for all the info guys, i did get it running but it definitely has an ECM problem because when the battery terminals are connected the fan starts up with the kill switch off and no key. I ran the vin number on the polaris website and it showed that the recall had been done (it has the silver surepower module) so i guess i will call the dealership and see if they can do it for free, if not i will be buying one on ebay for $150 which isnt too bad especially for an ECM. Thanks for all your help everyone!!!
 
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Old May 4, 2012 | 11:42 AM
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Even the replacement American made Surepower modules can go bad . Have replaced several of these. Some I've replaced three times counting the Chinese original ones on the same atvs along with a couple members have posted that they are on their fourth one! See if the dealer can call Polaris! I had most of the ones I replaced a couple times warrantied,only the ones that were too far out from the last replacement did I have trouble getting warranty consideration. OPT
 
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