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bobkyllo 
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Joined: 14 Sep 2009
Location: minnesota
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 Topic: Polaris atv troubles
Posted: 27 May 2024 at 3:45pm |
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I was asked to look at a 500 sportsman atv.
At first or wouldn't start or turn over. New starter and battery fixed that. Old starter drew a huge amount of current and barely rolled over. Battery was 5 years old no longer took charge.
Finally got it to run and noticed it wouldn't charge. New regulator fixed that.
About a week ago I finally got it to start. I had to blow air into the gas tank. Almost like it lost it's prime. Once it started it run good. Shut it off half hour later it would start. All day it would keep starting. Left it sit for a couple days and back to square under. Perhaps fuel pump is bad so I put a new one on. That did not seem to help.
If I blow air into the tank it seems to help start it but you still have to crank on it. Also seems to help to put a booster on the battery to help it start.
Any thoughts.
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jaybmiller
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Joined: 12 Sep 2009
Location: Greensville,Ont
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Posted: 27 May 2024 at 4:11pm |
can we assume you're replaced the fuel filter ?
What kind of 'fuel pump' ?
If it's a vacuum style like B&S gas engines, did you replace the vacuum hose from pump to valve cover ?
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3 D-14s,A-C forklift, B-112
Kubota BX23S lil' TOOT( The Other Orange Tractor)
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bobkyllo
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Posted: 27 May 2024 at 5:40pm |
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It is a b&s style vacuum fuel pump. I have not replaced the hose but my vacuum guage goes to negative 20 psi while cranking so that should be good I would think
Fuel filter is new also yes
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bobkyllo
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Posted: 27 May 2024 at 5:42pm |
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Am I going to hurt anything by switching to a 5 psi electric pump? Will I over feed the carb you think? The electric I feel is far more reliable then a vacuum pump
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HudCo
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Location: Plymouth Utah
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Posted: 27 May 2024 at 9:18pm |
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back flush the fuel tank in the on position and on reserve position , then suck the tank dry i a use a vacuumm pot and a pneumatic vacuumm pump then clean and rebuild the carb and set the choke clearance correct, also also make sure the stuck throttle switch up on the handle bars is not acting up throttle cable adjusment usually fixes that if it is acting up it will not start
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bobkyllo
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Posted: 27 May 2024 at 9:31pm |
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Hudco... check what on the handle bars? Can you explain that a bit more.
Like I say this will start and run but it starts very hard.
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HudCo
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Posted: 27 May 2024 at 9:44pm |
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their is a swicth in the throttle control that cuts the ignition if t gets stuck on full throttlebut iff the throttle cable gets out of adjustment, no freeplay in the thumb part it has the switch activated ireally dont know how to explain it very well inside that part . its like when its in front of me then i remember all the pertiicalars
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Codger
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Location: Illinois
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Posted: 27 May 2024 at 10:22pm |
Our Polaris Sportsman 400 does not have this I'm aware of. Been all over that machine through the years but about to put it down as the silent chain is skipping over it's engagement teeth, universals are loose in three of four wheel driveshafts, as is the prop shaft.
Been a working unit all it's life and dependable, but just worn out.
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A career built on repairing and improving engineering design deficiencies, shortcomings, and failures over 50 years now.
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HudCo
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Posted: 27 May 2024 at 11:09pm |
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not all the polaris has them some of the arctic cat stuff has them also same with the snowmobiles some have a magnet on the carb proximity swithch if the throttle is off and the swicth is still made up on the carbs then it wil shut it down same on efi stuff also
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bobkyllo
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Posted: 28 May 2024 at 12:30am |
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I'm just perplexed why it runs so well when it does run. Just hard to get stater.
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jaybmiller
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Posted: 28 May 2024 at 6:21am |
hmm. any chance the choke is 'wonky' ? Neighbour has a Cub Cadet with Kohler and when it's 'hard to start', I have to readjust the choke cable....
probably not the cause, but another thing to strike off the list ?
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3 D-14s,A-C forklift, B-112
Kubota BX23S lil' TOOT( The Other Orange Tractor)
Never burn your bridges, unless you can walk on water
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Codger
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Posted: 28 May 2024 at 6:22am |
On ours most times if setting overnight, a splash of gasoline onto the air filter element will get it to fire off and good for the many starts through the day afterward but the process needs repeated the next morning. I want to say our has a "Nikki"carburetor and I've replaced the diaphragm in the carburetor top a couple of times over the years to get this repaired and it works for a spell then back to the usual.
Engine runs very well once started.
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A career built on repairing and improving engineering design deficiencies, shortcomings, and failures over 50 years now.
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Clay
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Posted: 28 May 2024 at 10:42am |
To start my 2000 Polaris 250 xplorer, slightly crack the throttle.
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steve(ill)
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Posted: 28 May 2024 at 5:07pm |
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if carb is above fuel tank, the electric pump can help.... did that on a couple lawn mowers with briggs engine and gas tank below seat.
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Like them all, but love the "B"s.
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Tbone95
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Posted: 29 May 2024 at 6:09am |
“goes to-20 psi”. No it doesn’t 
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jaybmiller
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Posted: 29 May 2024 at 6:20am |
It's probably -20 " of Hg which is about 4 psi. if it really was -20 psi that's a super vacuum !!
I do have several pressure gauges that read +- psi
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3 D-14s,A-C forklift, B-112
Kubota BX23S lil' TOOT( The Other Orange Tractor)
Never burn your bridges, unless you can walk on water
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