2006 Sportsman 500 EFI problem

[Rockwerx]

Hello from Sherwood Park!

I have a problem with my quad missing/stuttering evey now and again and sometimes it even quits while out on a ride. It is acting like a sled with an iced up stuck throttle switch. When I had it in for this problem they adjusted the throttle cable and told me that was the problem, but the problem came back and readjusting the cable does not help. I have taken it to three dealerships for this problem and they have not been able to fix it. Has anyone else had a similar problem? Maybe a faulty throttle position sensor? It seems to do it only when it is hot (what atv is not hot after even a short ride?). Any feedback is welcome. Thanks!

 

[OnlyPolaris]

i can almost guarentee it is the throttle position sensor or the wires going to it. i had the exact problem. whenever my bike got warm it would do what you are describing. turns out the wires running to the tps were rubbed through. after fixing the wires the bike runs perfect. it has been ever sinse last year when i had the problem.

there is another possiblity. the electronic throttle sensor could need adjusting. if you take the top off the little box on your throttle, you will see to little contacts. if they are touching it will need to be adjusted so that they are 1/8" apart.

 

[Rockwerx]

Thanks for the tips! I will check the TPS wires for any obvious problems. I wish I knew if it was a bad wire or a bad TPS. I hate tracing intermitant wiring problems! Other than that I really like this quad! I will post my findings when and if I figure out the problem.

 

[Rockwerx]

The 500 has been parked since my last post. I was so sick of it failing on me right after it got a clean bill of health at the local Polaris shop I just left it at home and ran another quad.

The other day I put the key in and started it up. Ran it for an hour around the yard and it did not hicup. I was not able to rip on it like we would if we were out on a mountain trail so I still do not trust it.

Someone mentioned to me to check any codes that may have tripped. You have to turn the key on and off quickly to read the codes...anyway, I did not realize how it worked the first time and I can not get it to show me the codes again. What am I doing wrong? Very frustrating to say the least.

 

[Rockwerx]

Okay, not sure if I counted correctly but here are the codes it showed...34446471...hopefully someone knows what or if this will help me repair it or help put it out of it's misery! lol

 

[Rockwerx]

So does anyone know where to find out what these codes mean? My wife and son want their quads back! lol

 

[sumx54]

As mentioned above... I too am almost positive its the tps sensor wiring. Had this happen on two of my units. Call rainy creek powersports and talk to Doug ... 403.746.5000

 

[Rockwerx]

Thanks for the advice!

I am going to check a few things when I have some free time and if it does not work out I may let them try repairing it.

Someone mentioned to try unhooking one sensor at a time and then to check the codes that come up. Hopefully trying this should help me figure out where to start looking for the broken wire or failed sensor.

I still would like to find a list of what these codes mean.

 

[sumx54]

heres a start
Polaris Codes - ATV Forum - All Terrain Vehicle discussion for Honda, Yamaha and more ATVs

 

[Polaris500Sportsman]

Sorry to bring up an old post but having this exact problem when the machine gets warm, where abouts would i find the TPS wiring to see if has been rubbed thru?

 

[OnlyPolaris]

look on the side of the throttle body and you will see a sensor. just follow the wiring from the sensor. Usually it is rubbed through pretty close to the sensor.

 

[H2O]

They usually zip tie the wires to the TPS sensor plug in..... I would suspect the wires are rubbed through where the zip tie squishes the wires.

 

[Polaris500Sportsman]

How long does it take to get the TPS checked and fixed? mine needs set, i was out riding today for about 2 hours and after it got warm it just wanted to shut down and not run properly. After sitting for a while it fired back up and ran good for the rest of the trip.

 

[mudbug]

Sounds like your fuel pump is getting hot and shutting down, it cools of and fires right back up ??

 

[Polaris500Sportsman]

what would be a good way to keep the fuel pump cool? if thats what it is then it has to be the heat from the engine/exhaust.

 

[Polaris500Sportsman]

anybody have the CANADIAN part numbers for the NAPA fuel pumps?

 

[Polaris500Sportsman]

Got a new fuel pump from NAPA and gonna put it in and hopefully it solves the problem.

Before it would run good for about 2-3hours then it would act like it was out of fuel. The pump would sound really weak when it was priming and it would start for about 10-15minutes.

 

[Rockwerx]

Last season my Sportsman ran perfect all season. Put about 600 miles on it. The last ride it started to act up again but at least we were 50 feet from the pickup. We had a heck of a time trying to load it as it would only run for a few seconds at a time. When I got home it ran perfect again. We only used it around home this season.

I finally took it back to a Polaris dealer to see if they could figure it out this time. They found a couple of problems with the MAP sensor and the plug to it. Since I took it in the first time Polaris has come up with a repair kit for this exact problem. All fixed and ready to ride again!