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2002 Sportsman 500 HO, starts then dies

38K views 26 replies 10 participants last post by  LATEBURD HERE 2 HELP  
#1 ·
So my Sportsman was running great, then I parked it where I stopped to get off to talk to someone. It started right up but then died. Now when I try to start it, it did back fire 2 different times, and also will just barely fire. If it sits for a little while it will start and run for about 15 seconds then die and won't start for a while.

When I checked spark it was wonky so I put a new plug in it.

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#3 ·
and in the just in case category, try this:
 
#6 ·
sounds like a bad coil to me. if you have a manual there is ways to test it.
 
#9 ·
Jljbtm, would need some more info to help....but, were you riding for a while in the heat? May not be your issue but 800 and 700 EFI's are notorious for symptoms like you describe caused by heat related fuel pump failure. Full gas tank, rides great but after a long hot ride and you slow down or stop, won't stay running unless hard on the throttle. Cools off or put in cool gas, everything is fine. Replace with the appropriate fuel pump to solve the problem, there's a really good tutorial on here if this scenario fits. Give us some more details about the problem if not.
 
#10 ·
Well all I can tell you is it happened for the first time the other day and just like I described. I always start out with a full tank and after riding for a couple of hours on our way home before dark is when installed then it was very hard to start but once it started I had to keep the throttle up then it died a couple more times but then I finally made it home. I did see the video about adjusting the throttle cable and I haven't done that yet but I'll try it tomorrow. I'll have to look for it and find the tutorial that you speak of and maybe changing the fuel pump heck I don't even know where it is. Thanks for your help Jack

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#12 ·
Yeah pumps are inexpensive. Gas won't make a difference. Gas/alcohol additives will. I run Startron on all my engines, makes the small ones and atvs super easy to start even after weeks of sitting. As effective yet much less expensive than Seafoam.

Star Tron Enzyme Fuel Treatment


Luck and Enjoy! :cowboy:
 
#15 ·
While I can't guarantee it, what you are describing sounds exactly like what many of us 700/800 owners have gone through. As a test, I ran mine hard and fast on a hot day with a half tank, reproduced the problem, poured in cool gas, problem went away, reproduced again with fuller tank, let it sit to cool down, no problems. Was convinced at that point.

Here's the link to the excellent tutorial.

Get the carter pump, from my research more heat tolerant.
 
#17 ·
Don't go to the dealer, they don't sell the pump separately and want you to buy the whole $600 tank assembly. Pump model numbers are in the thread, any car parts place can get them but I got mine through partzilla I think because I wanted specifically the Carter brand. Thread is very informative but feel free to start another thread with specific questions if you have them after looking through it.
 
#21 ·
We went for a ride at mines and Meadows in Pennsylvania and road for several hours the whole time it didn't seem to be idling very smooth and noticed a strong odor of gasoline fumes no leaks but fumes and occasionally backfiring when decelerating but then after several hours it did stop and didn't want to start, but did start after a minute or two.

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#22 ·
Listen, guys, I Have a 2000 Polaris 500 4x4 and have all the same issues you all were having. I've replaced stator,CDI box, trigger, ignition, even tighten valves... all of that didn't work still was hard to start wouldn't stay running. I happen to read somewhere else about ramstator, bought it for 150 bucks gives you guaranteed spark when I hooked that bad boy up I shit you not months of carbs, tinkering and a lot of hours and boom! This Polaris I almost gave up on now comes to life!!!! no hesitation it runs like a brand new ATV! I seriously suggest to anyone who is going through these issues to make the small investment! I promise you that you won't be disappointed. I truly almost gave up! I had spark before but now... Holy cow it is like a whole new ATV! I hope this helps someone out there from spending countless hours and money chasing demons...