The reverse speed limiter thinks it's in reverse when it's in AWD - be nice to know how you wired it to bypass the shifter switch.

Try pressing the override switch when in AWD to see if the reverse speed limiter module is causing the problem.

 

The override button didn't do anything when it was happening. But this is right off idle it's having issues.

I ran through the wiring diagram and pulled out the heavy gray wire that goes to the AWD switch from the blade that's powered up only when in forward or override pressed in reverse and plugged it into a keyed 12v source. It could only power up the AWD system, unless something is shorted I can't see where it would power up the reverse limiter.

I put a video "short" on facebook but I can't figure out how to download and host elsewhere

Welcome to the forum

Thanks! I have a collecting problem and I love the interchangeability and lego-ness of the older Polaris so I'll end up with a few

 

99 Xplorer 300. Low usage - bought from original owner.


Engine seems to be in great shape. Fresh carb rebuild. Cold start , hot start, it'll fire right off on the first compression cycle. I've never had anything with a carburetor start this well!

Some backstory: The switch in the shifter doesn't work, so I didn't have AWD in reverse. I don't really care about the rev limiter deal in reverse (i'm fine with being speed limited in reverse). I ended up using the little breadboard thing to power the AWD switch directly. Now AWD works whenever I need it to - neutral, reverse , forward.

It has been like this for a few months now. Probably 8 trail rides on it without issue.

I think my issue may be related to snow. I was tooling around in the snow yesterday in 2wd for a while and it was running great. Probably the longest I've ever had the thing running WFO without letting off. Finally got it stuck and hit the AWD switch.

Once AWD turned on it started knocking and pinging horribly. I thought I blew the thing up running it wide open for so long. I have a slight hole in the exhaust and it was throwing sparks out of the exhaust when it would afterfire out the exhaust. It was also popping out the intake bad too. Of course we were quite a ways in the trail and my friend's 4 wheeler broke so I had to try to drag that out.

It was bogging out pretty bad but still able to move. If it got above mid range RPM it would start pinging and knocking real bad. Eventually we ran into somenoe else who got the broken one out. I had to put it into low range to be able to get it to move at all.

I got back to some hard pack and put it in 2wd and immediately it runs great. No pinging / knocking. Full RPM Range, full power.

Not quite sure what's going on here. I do not believe I'm hitting the neutral / reverse rev limiter - . I have hit that before, it doesn't cause bad things to happen. I wonder if something weird (shared ground? shared power?) is happening causing the CDI box to get all messed up and confused?

I don't think it's a stator issue. I was able to turn the electric fan on (I have it switched) , all 3 sets of lights and it was fine. Even idling in neutral it'll run good and rev fine, but if I turn on the AWD, anything over idle it'll start pinging and knocking / backfiring out intake / afterfiring bad through exhaust.

Just to make sure I didn't kill the thing, I ran it hard again in 2wd. Shut it off hot and just like normal, I just have to tap the starter and it fires off immediately.

Any toughs?

Welcome to the forum

 

Sounds like a poor connection somewhere was the cause and usually ends up being a poor ground.

 

Yep. I'm going to have to try to find my wiring diagram and see if there are any grounds shared between the AWD and the CDI box.

I'm guessing there's a single chassis ground that isn't happy.