Polaris Sportsman 700 idle issue

[Wolfdog2314]

Just throwing this out there if any one has some advice and dealt with one of these.

2005 Polaris sportsman 700 EFI

Won't idle. Fires right up. I can put it in gear and rip. Drives great. Stop and idle down, the idle will be very choppy and then die. It will fire right back up, but idle will still be erratic and then die. It also went thru a new battery in about 6 months and battery light would flash occasionally. Volts were at 11.6-12.2. The new stator fixed that issue. Now 12.6-13.5. But the idle issue is still there.

Pro caliber did their "diagnostics" and told me the stator was weak and if it's not that, then it "could be the fuel pump going out" That's all I was told. So I don't know if they did a fuel pressure test or what. Won't be going back there. They also wanted 800$ to replace the stator 

I've replaced:
Fuel filter
Spark plugs
Drive belt
Voltage regulator
Stator
Battery

I ordered a new fuel pump. Should be here this weekend. I'll try that. I also ordered a new TBAP wiring harness. It's a common harness with these bikes that goes bad.

Any other ideas? Or experience?

[KillerMiller]

Sounds like a carburetor issue. The idle jet may be clogged. I would take it apart and do a good cleaning and blow out the jets with air etc..

[Wolfdog2314]

Sounds like a carburetor issue. The idle jet may be clogged. I would take it apart and do a good cleaning and blow out the jets with air etc..

EFI!

Thanks!

[Buckmark]

trade it in on a Honda  JK
I wish i could help, good luck

[Zardoz]

Vacuum leak........

[Wolfdog2314]

Vacuum leak is something I didn't think of. I'll start looking around for one of those with some throttle body cleaner or something.

I tried attaching a short video of how it sounds. We'll see if it shows up

Thanks!

[Kittman]

Probably too much slack in your throttle cable tension.  Adjust and tighten it up.  Too much slack causes the ETC mechanism to think it is in a stuck throttle condition and will cause the contacts to be made which will kill ignition.  Had the same issue on my 2008 Sportsman 500 EFI and I solved my dying out issue.

Adjust up at the point where the cable goes into the thumb lever housing on the handlebar.

[Wolfdog2314]

Probably too much slack in your throttle cable tension.  Adjust and tighten it up.  Too much slack causes the ETC mechanism to think it is in a stuck throttle condition and will cause the contacts to be made which will kill ignition.  Had the same issue on my 2008 Sportsman 500 EFI and I solved my dying out issue.

Adjust up at the point where the cable goes into the thumb lever housing on the handlebar.

I'll try messing around with that again. I played with that before add I wasn't able to fix it. Only make it idle higher around the 1300 range to make it idle smoother.

Thanks for the ideas!

[Wolfdog2314]

New fuel pump in today, same issue

I adjusted the throttle cable some more. When adjust to 1/16-1/8 of freeplay as advised, idle is around 980. If I tighten it up to about 1180 rpms the idle is better, but still choppy. And also there's no free play in the thumb throttle.

My last ditch effort is this TBAP harness that a lot of people have had issues with. Should be here in a few days and I'll get that in and pray that's the fix!

[tracksoup]

We run Polaris machines (they are all 2-6 years old) at work and the most common problem we have had with them is the TPS (throttle positioning sensor) every one of our 6 machines have had this problem. Not sure how the year of your machine is set up but if it has a TPS I would strongly recommend checking it.

[Wolfdog2314]

No luck with my final attempt.

So, Honda.... I've always liked those Grizzleys too. Might have to go look. I need a good dependable rig by next week!