Engine Won't Start - Polaris ATV Forum
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post #1 of 12 (permalink) Old 05-14-2019, 03:34 PM Thread Starter
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Engine Won't Start

Need some serious help here..
1997 Polaris Xplorer 500 has a new starter, new stator, new aftermarket carburetor, new battery, new fuel filter, new air filter, new ignition coil, and new flywheel but it just won't start. Press the start button and it cranks and cranks but never turns over to fire anything out of the exhaust. I've tested several different things i.e. compression check, gas down the sparkplug hole check, spark check etc and nothing seems wrong. Had it at a shop and they got it to start long enough to get on the trailer with all the new pieces but brought it home and wouldn't start. I'm at a loss for words and parts. Any ideas whatsoever.. or any questions I am willing to answer because I've seriously tries everything besides buying straight 3 grand OEM replacement parts. Thanks.
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post #2 of 12 (permalink) Old 05-14-2019, 06:19 PM
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2 stroke or 4 stroke? How much compression, what is the number? What does the shop say about it? You should be able to call them and ask wtf......

Will it start and run on starting fluid?

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #3 of 12 (permalink) Old 05-14-2019, 06:27 PM Thread Starter
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It's a 4 stroke and I'm not sure what you mean by compression or number.. it's a 500cc and I'm gonna try that (starter fluid) tomorrow. I'll let you know what I find.
Shop said they replaced those above parts and it started up (they rode it on the trailer). Brought it home and it wouldn't start but life happens, and I couldn't get back to it until months later so here we are.
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post #4 of 12 (permalink) Old 05-14-2019, 09:26 PM
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If a compression check was done, it will produce a pounds per square inch (PSI) number. 90, 110, 150 and so on.

So to be clear, it would not start so you could drive it off the trailer after the shop worked on it right. It has been sitting since? Simple things first. Is the fuel turned on? Kill switch should be in the run position since you said it cranks over. Did the shop have trouble getting it started? If it started right up for them it has to be something simple that has been overlooked.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #5 of 12 (permalink) Old 05-15-2019, 07:33 AM
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Try a new spark plug first.

If the fuel was left turned on between parking and trying to restart, it could be flooded - hold the throttle wide open and crank for awhile to see if it starts - if not, get some starting fluid and spray into the intake while holding the throttle wide open.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

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post #6 of 12 (permalink) Old 05-15-2019, 08:39 AM Thread Starter
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It has a new spark plug and by compression test, I just put my thumb over the spark plug hole to see if it actually pushed air back. The shop had a lot of trouble just trying to get it started so I think they just used starter fluid, got it rolling, and just handed it off. But I just tried starter fluid: it finally starts and turns over but dies immediately so to me that sounds like lack of gas. Kill switch is off, battery is new and charged, new sparkplug, shes in neutral.. I've been dealing with this for about a year now and have tried all of the new stuff.
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post #7 of 12 (permalink) Old 05-15-2019, 12:37 PM
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30 to 40 pounds of air pressure will push past your thumb - it needs to be about 90 to start - starting fluid will start low compression engines because it has a higher expansion rate than gasoline (fills a larger volume area with less fuel)

You need to find a different repair shop - a good shop would have told you what they found and what it was going to take to fix it right.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #8 of 12 (permalink) Old 05-16-2019, 06:01 AM Thread Starter
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How much fuel should be coming through the fuel line? I'm not getting anything forceful, it's more of a trickle and I'm not sure how to diagnose a bad fuel pump or not.
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post #9 of 12 (permalink) Old 05-16-2019, 06:27 AM
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Just a trickle is fine for low speed - might become a problem at high speed or under load for an unspecified period of time.

The fuel pump should produce 3 to 4 PSI on a carburetted engine.

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #10 of 12 (permalink) Old 05-16-2019, 06:57 PM
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Quote:
Originally Posted by dkarr13 View Post
How much fuel should be coming through the fuel line? I'm not getting anything forceful, it's more of a trickle and I'm not sure how to diagnose a bad fuel pump or not.
You should be able to tell the difference between engine off and engine either running or cranking over. Engine off will be a trickle.... ish. If the engine will start or while cranking the engine you should see the pulses of the fuel pump. Like Latebird said, not much force behind it, but you should be able to tell the difference.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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