06 500 efi sportsman wont hardly run, backfires - Polaris ATV Forum
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Old 03-02-2013, 02:27 PM
hiljak's Avatar
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Location: Kentucky
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Angry 06 500 efi sportsman wont hardly run, backfires

Ok, I've been dealing with this for years now. At one point my sportsman sat around for about 2 yrs. I probably started it a total of 5 times. The last time I went to start it, it wouldnt hardly start, and when it did, it sputtered really bad when running. Then it wouldnt start back and the fuel pump failed.

I replaced the fuel pump, fuel filter, spark plug, and fuel injector. That was two years ago. It didnt help. I even took it to a dealer to work on it. I went to pick it up, and it still ran like crap. He sprayed a couple of cans of carb cleaner in the air filter with it wide open and it ran good up and down the parking lot. I've rode it as much as I can since then, and a couple of times it seemed ok..for awhile.

Heres what is presently happening, which isnt much different than the past few years. I can get it started initially, but if you give it gas, it dies. I spray carb cleaner in air filter, it runs for a few minutes, then starts bogging down, sputtering, and quits if you hold the throttle open. I wear my thumb out working the throttle to try to keep it running. It will surge forward a couple of feet, then nothing...work the throttle, surge, nothing....if it does go anywhere, it backfires a lot also. I'm fed up.

Any advice out there? Besides pushing it off a cliff?
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Old 03-02-2013, 03:29 PM
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I would start by getting rid all the old gas and fill with new. If you did not buy it new check to see if someone added an in line fuel filter and replace. Check, clean or replace the fuel shut off valve (often over looked). Just had this problem with my snow blower. Shut off valve all gummed up.

Recheck every thing you already mentioned again. Also check for a strong spark, coil may be weak. Worse case, check compression, and timing.
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Old 03-02-2013, 04:00 PM
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Welcome to the board!
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Old 03-02-2013, 06:20 PM
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The only guess I have is the air flow senser in the throttle body. Not sure if yours is the same, but the older ones had problems with the wires in the harness breaking near the connector plug. Mine (04 efi) has had problems similar to yours and I usually remove the throttle body and clean and it runs good, but I think I need to replace the pigtail on the senser.
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Old 03-03-2013, 10:22 AM
Russ C's Avatar
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Tbap sensor wiring harness , take seat off, pull and twist on t-bap harness, take wires out of harness and check for broken wires, they sell a better replacement for it on e-bay, heavier wires,
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Old 03-03-2013, 11:41 AM
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Where you at in Kentucky hiljak? I'll come buy it and you won't have to worry with it anymore.
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Old 03-09-2013, 04:11 PM
hiljak's Avatar
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Thanks guys, got it fixed today!! It was the tbap wiring harness causing all the trouble. I got lucky too, because my polaris dealer is also a large car dealership. They didnt have the part in stock, but he went to the garage and found a plug that fit perfectly from some hyundai car. Either way, after 3 yrs i can finally ride again, and I can put some miles on this thing. 210 miles on an 06, it need it!!
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