2006 Polraris Sportsman 500

[elksnout]

Replaced starter, starter solenoid and Bendix cause the old girl wouldn't start. While I had the some of the plastic off I replaced the fuel filter. Turned the key Saturday morning and if fired right up. Rode it around  the place and just let it run for awhile. Multiple times that day I would just go hit the key and it started like nobody's  business. Went out Sunday for a ride and all it does is turn over and not start. Just turns over like it's out of gas. Put fresh gas in it on Saturday. Battery has been on a tender and  reads 12.87 on the meter. WTH? Any ideas?
 

Elksnout

[dscubame]

Carburetor jet is my guess.

[Wolfdog2314]

I assume it’s Carbureted? Give that a good cleaning.

Fuel pump after that? When u turn your key one position over can you hear it pumping fuel?

[Mudman]

Batt voltage seems ok but I would start there.  Increase voltages.  Check coil wires n plug wire for breaks.  So check for spark first thing!  Stator issue?  Volt reg.?  Also things like faulty fuel tank cap vent?  Pinched fuel line?  Pull plug, does it smell of heavy gas?  Start at plug..

[robodad]

Turn off or bypass the kill switch, sounds to me like a wire came unplugged or the switch went bad !

[Katmai Guy]

My quad did the exact same thing a couple of years ago. A chunk of rust from the inside of the fuel tank cap jammed up the jet carb.  There is no fuel filter on my Yamaha Kodiak so that's how the mechanic said it got by.  If yours sat for a long time it might be gummed up fuel also.

[CP]

It turns over (I’m assuming it turns over vigorously) – so it isn’t the battery.   

To start a motor needs
1.   Fuel
2.   Air
3.   Ignition source

I’d start with #3 – check for spark at the plug.  See what you find then reassess

[elksnout]

It's fuel injected, no carb. After sitting all night and day on the battery tender I have next to 13 volts tonight. Pulled the outlet fuel line off the filter and there's fuel there. However the volume of fuel did not increase while I was hitting the key turning it over??  With everything working as it should, shouldn't the fuel been shooting out of the filter?

Here's the thing. I rode it onto the garage, shut it off, left it overnight and it would not start again. Looked for a wire that may have come loose, etc.

Dummie disclaimer....how do I check for spark??

Thank
Elksnout

[dscubame]

Fuel pump and injectors to check since no carb.

[Wolfdog2314]

Pull the fuel line off of where it enters the fuel filter. Turn the key. Should push a good amount of pressurized fuel out the line. Should also just be able to hear the fuel pump engage when you turn the key before you start it. (Buzz sound) If you do end up replacing the fuel pump, it’s a piece of cake. I just did one on an 06 700 efi.

https://www.amazon.com/gp/aw/d/B00T7BFYX6/ref=sspa_mw_detail_0?ie=UTF8&psc=1 This is the one I used.

I’d double/triple check all wiring. A high % of EFI engine issues are electrical.

[elksnout]

Wolfdog I'll try that tomorrow night.

Thanks
Elksnout

[elksnout]

I checked and it has spark. Does this rule out the starting system?

Thanks
Elksnout

[Kittman]

I would check the throttle ETC cable adjustment, there may be too much slack and might need to be adjusted-tightened.  If you try to start with thumb pressure on the throttle lever and starts and runs,  but then dies when released that could be the issue.

[elksnout]

Bringing this back up.....

Finally got back to working on this. Here's the story.

Installed a brand new starter, Bendix and solenoid. Fired right up after installing those three items, rode around the property. Washed it, rode some more. Started throughout the day like it should. Parked it in the garage. Go out later for a ride it will not start. Just cranks and cranks. Checked for spark. Yep, it's there. Installed new fuel filter and pulled the line off and turned it over. Plenty of gas flowing. Have checked multiple times for any plugs, wires, cables, etc. which may have come undone. Just this morning I installed new spark plug and (not cheap) battery. Still just cranks like a bandit but will not light up.

So pissed right now I'd like to put a bullet in it. Dealer or local shop (Pro-Caliber) will just be an exercise in frustration. What am I missing?? The wrench icon (service) illuminates on the speedo while it's cranking but I can't remember if it should and that if it goes away once the motor starts?

Elksnout

[Woodchuck]

The wrench icon (service) illuminates on the speedo while it's cranking but I can't remember if it should and that if it goes away once the motor starts?

Elksnout

Likely just a bulb check.

[jackelope]

You can have fuel but not enough fuel PRESSURE to start it. Just because there's fuel there doesn't mean the fuel pump is ok.

[Buckmark]

You said you have spark but is it good spark? Blue and crisp when it cranks over? Have you tried swapping in another spark plug? Maybe pull the plug and spray some starter fluid in put the plug back in and see if it fires off.
K.I.S.S
Keep it simple stupid (not that your stupid, its just a phrase)
I have had techs go in circles because they assume something or skip the little things

[elksnout]

You said you have spark but is it good spark? Blue and crisp when it cranks over? Have you tried swapping in another spark plug?      Maybe pull the plug and spray some starter fluid in put the plug back in and see if it fires off.
K.I.S.S
Keep it simple stupid (not that your stupid, its just a phrase)
I have had techs go in circles because they assume something or skip the little things

Yes. Installed a new plug this morning as stated in post. Thanks

[Mudman]

I have had issues like this before and except for 1X it has always been a carb/fuel issue.  Gummed up jets.  Pilot jet.  Pull jets and clean then try.  Next would be what was already said-weak spark.  Had a Suzuki with stator issue which resulted in a weak (??) spark.  It should be a significant spark capable of arcing and not just little color at plug electrode.  Keep playing you will get her running!

[elksnout]

I have had issues like this before and except for 1X it has always been a carb/fuel issue.  Gummed up jets.  Pilot jet.  Pull jets and clean then try.  Next would be what was already said-weak spark.  Had a Suzuki with stator issue which resulted in a weak (??) spark.  It should be a significant spark capable of arcing and not just little color at plug electrode.  Keep playing you will get her running!

Old beast is fuel injected. No carb. Going to tink on her in the morning. Think I'll pull back out the new plug and test again for spark. Is the best way to pull the plug and reattach the spark plug wire then hit the key? Do I need to ground it?  If spark is solid, I'll pour some fuel down the spark plug hole and see if it will fire.

Thanks
Elksnout

[Mark Brenckle]

Just spray a little bit of carb or break cleaner in the spark plug hole and replace the plug. If it runs for a second or two, its fuel related. 

[SniperDanWA]

Just spray a little bit of carb or break cleaner in the spark plug hole and replace the plug. If it runs for a second or two, its fuel related.

Yeah.  I’ve had carb issues on several items.  I found a great carb/fuel additive at OReilly’s in a blue can.  It goes right through the fuel into the carb and cleans as it goes.  If I had a can, I’d go get the name, but I’m out.  It’s no joke, it works awesome.

[elksnout]

Pulled the (new) spark plug and it was dry? Checked for spark and I had  nice crisp blue showing. Sprayed starter fluid down the pipe, reinstalled plug and hit the key. She fired right up for 2-3 seconds.

So now I'm pretty sure it's a fuel issue. Where is the hell is the fuel pump on that thing? Yikes it must be buried.... I do have fuel going out the filter with a line off and turning the key.

More thoughts and/or direction??

Thanks
Elksnout

[jackelope]

Googler. 

https://www.polarisatvforums.com/forums/polaris-atv-how-tos/28010-troubleshooting-2006-sportsman-700-fuel-pump-fuel-gauge-fuel-pressure-regulator.html#/topics/28010

[bigdub257]

Just spray a little bit of carb or break cleaner in the spark plug hole and replace the plug. If it runs for a second or two, its fuel related.

Yeah.  I’ve had carb issues on several items.  I found a great carb/fuel additive at OReilly’s in a blue can.  It goes right through the fuel into the carb and cleans as it goes.  If I had a can, I’d go get the name, but I’m out.  It’s no joke, it works awesome.

Seafoam?

[elksnout]

She's running   Google told me the fuel injected 500's have the fuel pump in the tank. So I tear apart the old girl even further to see where the pump has access. I removed the clamp off the fuel line so I could see if gas pumps while I hit the key. When I did she fired up!! WTH? Secured everything and she runs like a top.

Now what?  Was their a vapor lock? Loose wire? I did spend some time checking all wires and connectors, etc. But the check engine light stays on so something is still wrong? Kind of nervous taking it over to eastern Oregon for archery elk like that if you know what I mean.

Elksnout

[JBar]

If it's the wrench light its probably just the service interval is up, Google now to reset it, if it comes back on after that put a piece of electrical tape over it. But seriously probably just telling you the oil change is due.

[Mudman]

I would check/clear the return /vent line, whatever it is.  So don't happen again.  Reset light n go ride!

[elksnout]

If it's the wrench light its probably just the service interval is up, Google now to reset it, if it comes back on after that put a piece of electrical tape over it. But seriously probably just telling you the oil change is due.

The wrench light goes off once it starts. The check engine warning light stays on....

Elksnout