Tollster
Veteran Member
1996 Polaris sportsman 400 2-stroke. Run like a champ, then it will die and leave you sitting, sometimes it will refire, other times draining the battery. Checked fuel flow, looks as good as new, spark appears fine, plug is wet, have also replaced plug, but sill will not refire, two days later, it'll run like a top, then leave you sitting, could be fifty yards sprint, or 1/4 mile. Swapped fuel out, with high test, still nothing, drop carb, checked bowl, no debris, no fungus, no gum, jet look clear, only normal tarnishing.
Also check fuse panel, no corrosion, normal oxidation on aluminum contacts showing no sign of moisture every entering
WTF
The only thing I can possibly think of is the reverse by-pass switch has given me trouble for about 5 years now.
NORMAL OPERATION: Place quad in reverse, back up, a governor engages at low RPM to prevent the mentally inept from hurting themselves, you can then push the yellow switch on the left handle bar to bypass the governor, allowing full range of acceleration in reverse when needed.
My issue with by-pass: Place quad in reverse, instant stall, push the bypass switch, then put unit in reverse, full range of acceleration and no stalling...
I thought today I would do a final fuel system check, verifying flow, and checking the bowl one more time, I cleaned the exterior of the carb, and flushed the bowl, then removed the jets, and am soaking over night in 3 parts water, 1 part pine-sol, for a like new carb.
Will reinstall and see what happens...
I do not believe its compression, and cannot get my guage on the top end due to clearance issues. Its tight and pulls like a new chainsaw, it also only has 900 babied miles on it, its used for shores, hunting, and fishing by an adult to has owned it since new, also garaged and covered...
Any other suggestions?
Also check fuse panel, no corrosion, normal oxidation on aluminum contacts showing no sign of moisture every entering
WTF
The only thing I can possibly think of is the reverse by-pass switch has given me trouble for about 5 years now.
NORMAL OPERATION: Place quad in reverse, back up, a governor engages at low RPM to prevent the mentally inept from hurting themselves, you can then push the yellow switch on the left handle bar to bypass the governor, allowing full range of acceleration in reverse when needed.
My issue with by-pass: Place quad in reverse, instant stall, push the bypass switch, then put unit in reverse, full range of acceleration and no stalling...
I thought today I would do a final fuel system check, verifying flow, and checking the bowl one more time, I cleaned the exterior of the carb, and flushed the bowl, then removed the jets, and am soaking over night in 3 parts water, 1 part pine-sol, for a like new carb.
Will reinstall and see what happens...
I do not believe its compression, and cannot get my guage on the top end due to clearance issues. Its tight and pulls like a new chainsaw, it also only has 900 babied miles on it, its used for shores, hunting, and fishing by an adult to has owned it since new, also garaged and covered...
Any other suggestions?
