polaris fuel injector removal

tony97gt · #1 (**permalink**) 05-25-2010, 11:37 AM

I have searched and couldn't find a definate answer for this.

I bought a 2005 Sportsman 800 with a full Muzzy Dual exhaust. The previous owner said he ran the bike on race fuel/AV gas for it to run good. I changed out the plugs and put a new exhaust gasket recently due to a leak. But I am still having a problem with the bike running like crap when it gets heated up, when running on regular fuel(93). Eventually it bogs down and the motor gets very loud after about 5 minutes of running. It gets to the point where I cant go over 20mph and if I give it more throttle it bogs down almost to a stop. My friend is telling me it is running lean because of the exhaust and I need to add an optimizer.

I recently purchased a Muzzy optimizer, but when I tried to install it I ran into a problem. I couldn't figure out how to remove the fuel injector wire off the top of the injector. There is a metal clip which I am unsure of how to get off. I am afraid of breaking it if I mess with it too much, so I was wondering if someone can off me some advice on how it comes off. I tried pushing it in and pullin up on the wire, but it didn't come off.

Any help is appreciated. Thank you.

eatmydust · #2 (**permalink**) 06-19-2010, 05:21 PM

I dont know if this is the same on my 07 500, but on mine there was a tab on the front of the plug that i had to push in then the plug came out. it was hard to get at reaching under the tank.

tony97gt · #3 (**permalink**) 06-22-2010, 05:09 AM

Thx bud. I actually discovered that I was trying to remove the harness right on top of the injector, which is incorrect. I looked a little farther up the line and found the proper spot to remove it an plug in the optimizer.

Azegthoth · #4 (**permalink**) 02-03-2012, 03:49 AM

The injector harness had epoxy over the metal tab and inside the injector connector. You have to chip it away and you will eventually be able to remove the clip and remove the connector from the injector. I had a broken wire in my #2 injector connector. Bought 2 new connectors, made my own harness, and havent had a problem yet.