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Discussion Starter #1
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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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?
 

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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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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.
 

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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.
 

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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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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.
 

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Discussion Starter #8
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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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.
 

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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.
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.
 

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Discussion Starter #11
I can definitely tell a difference in the fuel line so I don't believe that's the issue so I'm back on the carb.. I soaked it in carb cleaner, saw daylight through the jets, and slapped it back in and still didnt get it to fire. Is there anyway I can get an OEM carb without paying $450? Or maybe somewhere that I can try to slap an OEM carb to see if that's the issue?
 

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Nope - we are back to compression - how many PSI does the engine have when cranking over with the throttle held wide open?
Im in a similar boat. Ive got a 2005 polaris ATP 500ho and seems to have a weak spark to me. New cheap carb, new fuel pump, Measured 500v from the cdi out, tried a different stator / pickup with the same results (185 ohms on trigger and 0.3 on stator), different coil pack (0.2 on primary and 12k on secondary, adjusted valves to 0.006, compression is 50 on stone cold and 70 with a little oil. Swapped ECM, Is it just the low compression numbers? Factory service says 50 - 100 psi. The kicker is I do not have the original cluster but was told it ran without it but no 4x4. It has been sitting for around 4 years. Starter fluid doesnt seem to have any impact.

Thanks for any help and sorry if I hijacked. Didnt see him responding and really need some expert advice.
 
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