Little Surprize after Maintenance - Polaris ATV Forum
ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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post #1 of 25 (permalink) Old 07-08-2019, 04:24 PM Thread Starter
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Little Surprize after Maintenance

Today I finally did all the fluid/air change maintenance on my 2008 PS 500 HO EFI Touring. This afternoon started it up and went for little ride on the property, not even a mile. As I was pulling into the driveway to my shop the ATV started feeling sluggish and then just died, WTH now.

It will start up idle just fine, but soon as you put it into gear then give it a little throttle it just dies. I tried limping it back into the shop with out any luck, ended up having to push it in there. Also got a couple flashes of check engine on the display and noticed one time I believe it said "WAIT" on the display, IDK on that for sure.

I let it set for little bit and started it up again seemed to be running fine, I backed out of the shop and put it in (L) gear giving it just a little throttle and then it just bogged down and died. This time I did manage to keep it running enough to limp it back into the shop with out having to push it.

I checked the battery because I've read weird things can happen on these EFI machines if the battery is to low on voltage. With ATV not running battery show's 13.2 volts, then I checked it from idling - 3400 rpm showed a constant 14.3 volts on my multimeter, this was in PARK and in N positions. Got any ideas what's going on with my machine? I've owned this 08 PS 500 EFI for about a month now with very little riding and this happens this afternoon after my maintenance. This is the first EFI I've ever owned.

Tony

2008 Polaris Sportsman 500 HO EFI Touring AWD
Pearl White/Silver Trim
PowerMadd Handguards/PM Mirrors
SuperATV Front & Rear Tube Brush/Bumper Guards (Wrinkle Black)

2005 Suzuki Eiger 400 4x4 Auto
Raider Cargo Rear Storage Box
Power Madd Hand Guards/ PM Mirrors
UNI Air Filter
Deestone Swamp Witch ATV Mud Tires
Yamaha Raptor 660 Petcock Mod

2008 Arctic Cat 650 H1 TRV 4x4
(SOLD: Dealership Buy Back, ( a heck of a story)

Last edited by T. Texas Tony; 07-08-2019 at 06:12 PM.
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post #2 of 25 (permalink) Old 07-09-2019, 07:52 AM
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Check your fuel pressure - should be about 45 psi

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post #3 of 25 (permalink) Old 07-09-2019, 12:37 PM
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Did you wash it? Maybe something got wet?!?!?

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post #4 of 25 (permalink) Old 07-09-2019, 02:19 PM
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I'm with Latebird, sounds fuel related. Do we have fuel filters on these quads?

must modify
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post #5 of 25 (permalink) Old 07-09-2019, 02:21 PM Thread Starter
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latebird I've been suspecting that possibly the fuel pump is going out all day long. Something to think about while I was mowing all day. I have no idea how to check fuel pressure on this EFI, this is my first one.

bp405 No wash job, I just changed the oil/oil filter, new air filter,new front DD diff fluid,and changed out the AGL trans fluid. One good thing about it breaking down on me it happened with in about 10 foot of my shop door instead of out in the field.

I tried this afternoon to see if any codes would come up, but apparently I'm doing something wrong, because I get nothing coming up. Here's what I do per the owners manual instructions. It says place trans in PARK .Stop the engine (I tried with engine running then turn it off then back on and also just turning the switch to on then off with engine not running to start with).

Turn the key switch to ON position.

Turn the key switch off and on three times in less than five seconds. The word "WAIt" will appear on the screen.

I get no "WAIt" showing on the screen at all, just my regular display of my mileage,clock,or RPM whatever sequence it's in at the time I try. I bet I tried it at least a dozen times with no luck getting into the code sequence section to check for error codes.

Also this afternoon I started up the ATV and increased the throttle just a little bit, it would hold a higher RPM like in the 2400-2500 RPM range and would not come back down to idle when I released the the throttle. I had to slightly fan the throttle to make it come down to regular idle RPM range which on mine is showing 1170-1190 RPM at idle.

Tony

2008 Polaris Sportsman 500 HO EFI Touring AWD
Pearl White/Silver Trim
PowerMadd Handguards/PM Mirrors
SuperATV Front & Rear Tube Brush/Bumper Guards (Wrinkle Black)

2005 Suzuki Eiger 400 4x4 Auto
Raider Cargo Rear Storage Box
Power Madd Hand Guards/ PM Mirrors
UNI Air Filter
Deestone Swamp Witch ATV Mud Tires
Yamaha Raptor 660 Petcock Mod

2008 Arctic Cat 650 H1 TRV 4x4
(SOLD: Dealership Buy Back, ( a heck of a story)
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post #6 of 25 (permalink) Old 07-09-2019, 03:18 PM Thread Starter
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Quote:
Originally Posted by gearheadesw1 View Post
I'm with Latebird, sounds fuel related. Do we have fuel filters on these quads?
Mine has a metal fuel filter and it's located toward the front of the ATV. I'm guessing it's the original one from the factory, I received no maintenance records when I bought the ATV about a month ago.

According to the owners manual I believe it says to change fuel filter out around a 1000 miles or it may be greater mileage than that, I don't remember for sure. My odometer has 776 miles showing, so I didn't mess with changing that fuel filter out this time.

Tony
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2008 Polaris Sportsman 500 HO EFI Touring AWD
Pearl White/Silver Trim
PowerMadd Handguards/PM Mirrors
SuperATV Front & Rear Tube Brush/Bumper Guards (Wrinkle Black)

2005 Suzuki Eiger 400 4x4 Auto
Raider Cargo Rear Storage Box
Power Madd Hand Guards/ PM Mirrors
UNI Air Filter
Deestone Swamp Witch ATV Mud Tires
Yamaha Raptor 660 Petcock Mod

2008 Arctic Cat 650 H1 TRV 4x4
(SOLD: Dealership Buy Back, ( a heck of a story)
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post #7 of 25 (permalink) Old 07-10-2019, 12:19 PM Thread Starter
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I called my local Polaris dealership this morning to see if my part I ordered last week came in (oem work light switch). Partsman said by Friday, anyway I ask them about doing a diagnostic test on my PS 500 HO EFI to see what the problem was. Service manager what's it doing, I told him and I said I suspect the in tank fuel pump is on it's way out, not for sure on that.

He sure was wanting me to bring it in to them lol. I told him all I wanted was a price for the diagnostic test and he quoted me $160.00 USD just to tell me what's wrong with it. I told him I will try to figure out first what the fuel pressure is before I do anything.

I talked to a mechanic buddy of mine this morning also and he is supposed to come by late this evening with his pressure gauge and we'll see if we can figure out what we need to do then to get a pressure reading.

Service manager would not tell me where to connect pressure gauge, but from the looks of the picture in the service manual you can connect where the fuel line connects to the fuel rail. Figuring out a good connector may be the problem though, we'll see.

I looked in the service manual and it's saying a fuel pressure of 39+3 psi for my 08 PS 500 HO EFI.

Tony

2008 Polaris Sportsman 500 HO EFI Touring AWD
Pearl White/Silver Trim
PowerMadd Handguards/PM Mirrors
SuperATV Front & Rear Tube Brush/Bumper Guards (Wrinkle Black)

2005 Suzuki Eiger 400 4x4 Auto
Raider Cargo Rear Storage Box
Power Madd Hand Guards/ PM Mirrors
UNI Air Filter
Deestone Swamp Witch ATV Mud Tires
Yamaha Raptor 660 Petcock Mod

2008 Arctic Cat 650 H1 TRV 4x4
(SOLD: Dealership Buy Back, ( a heck of a story)
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post #8 of 25 (permalink) Old 07-10-2019, 12:53 PM
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Adjust throttle cable? mine 09 .850 efi, been acting up the same or similar to yours ...
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Last edited by TheStatelineATV; 07-10-2019 at 01:12 PM.
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post #9 of 25 (permalink) Old 07-10-2019, 01:26 PM
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I don't think that machine has a Schrader valve to test from like some models. If not, you gotta T in for the gauge between the fuel rail and supply line. If you pull the tank to replace the pump and regulator you might as well change the in-line filter too while its easy to get to. Be sure to pour a little fuel in the new filter to wet it before installing to prevent the filter from possibly tearing internally on initial fuel priming.
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post #10 of 25 (permalink) Old 07-10-2019, 01:29 PM
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Quote:
Originally Posted by TheStatelineATV View Post
Adjust throttle cable? mine 09 .850 efi, been acting up the same or similar to yours ...
Yeah, make sure you've checked the easy stuff first. Make sure the throttle safety switch/cable adjustment is right. Needs about 1/8" free play. That will make it cut out like you describe.
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