I have a 2006 Polaris Sportsman 700 EFI. over 300 hours and 4500 miles. The color if the quad needs to be yellow because i think i have a lemon....but anyway, heres the problem.
Since we first got the quad we have had an intermittent problem that makes me wonder why i bought another polaris product. Anyway, what seems to happen is the machine looses a cylinder, spits, sputters, pops thru the airbox, backfires, wont idle, and sometimes wont even start. On a recent ride, i was able to cover up the intake tube, and the idle smoothed out, and it seemed to rev up fine! Take my hand off of it and it was lucky to hold a rpm. I can have the throttle wide open, and it pops thru the airbox and is lucky if the tach reads over 1300 rpm. But every time this has happened...we have let the quad sit for 5-10 minutes- enough for more polaris jokes, f bombs, and a snack, and she starts right up just like nothing ever happened!
Take this into consideration:
Code 41 and 42 have been comin and going for the first year. Taken the bike into the dealer with our ext warranty and they dont know whats wrong with it. Time after time, they say they cant re create the problem. They replaced the tbap connector wires. Bike ran great for 5-6 rides then issue came back. This was about a year ago, and we've been "dealing" with the problem since then.
2 weeks ago, the dealer found what was to be our problem! 3 inches below the wires that were cut a year ago, the wires rubbed thru the plastic coating and were shorting out. The dealer ashured us that he would never see us again because the bike would run brand new. Well it does seem to run better and have a little more et up and go, but 5 hours into my last ride the same problem came back. It happend 3 times in the 10 hour ride.
Latley, it seems to happen when its in low range, or speed under 15 mph, rock crawling, slow trail riding. But i can slide around corners, ride it hard, floor it on every straight away, and it never skips a beat.
Ive spent the past 2 nights on this site reading how the fuel could be boiling, or how there may be a vapor lock, which is kind of what i refer to as the problem. We have taken the tank off, replced the in line fuel filter, and put some of that reflective heat tape on the bottom side of the gas tank. When i was reading about the fuel pump, one thing made my situation a little different. Normaly, when you turn the key on, the fuel pump primes its self. When my bike "acts up" meaning its starting to spit and sputter, and i turn they key on, the fuel pump noise sounds week and is on for a little longer, like its laboring. The dealer said the fuel pressure is "acceptable" but didnt give me a number. Now to me, it's clear that the psi is acceptable because the bike is running fine, but when it starts to spit and sputter, is when i think the fuel pressure drops. Right? Argue with me on this...
Sorry for writing a book, im sure i forgot a few things aswell, but i thouht id pick some mroe brains and try and get the ball rolling to fix this.