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This is a description about how idle problems were solved on a Polaris Sportsman 500 EFI 2007. I hope this post can be helpful to members of the forum and others.

I bought a used Polaris Sportsman 500 EFI year 2007 in November 2011. It only had 6 hours on the meter an had obviously been sitting a lot. After i had run it for a few hours i started to have problems with the idle. The problems can be divided into three.

1. Sometimes the machine did not want to idle at all. It died when i released the throttle, sometimes this happened immediately or after a few seconds of idle.

2. Sometimes the idle stuck at around 1600 rpm and did not come down to correct level about 1140 rpm.

3. When it did idle the idle wasn't very stabile. It went up and down between 1100 – 1500 rpm.

Problem number 1 was quite easy to fix. The throttle cable tension was to loose causing the contacts in the ETC switch to make contact. This is a safety mechanism that prevents the engine to run if the cable is stuck with the throttle in open position. But this also happens if the cable tension is to loose. I tightened the cable tension and problem number 1 was fixed.

Problem number 2 and 3 were more difficult to solve. I checked all wiring from the IAC, the TPS and the MAP sensor to the ECU. Found that the insulation on one of the cables from the TPS was broken. Ok here we have it i thought. I isolated the wire but the problems remained. Then i tried cleaning the IAC and the MAP sensor and all connectors. It did not help. I bought new (used) IAC and MAP sensor. No luck. Finally i bought the TPS test connector https://polaris.spx.com/Detail.aspx?id=182. With this tester and a multimeter i could se that there were jumps in the volts on my TPS when i moved the throttle from closed to wide open. I bought a new (used) TPS and problem number 3 was solved. The idle became stabile at around 1180 rpm.

Problem number 2 still remained unsolved and no matter what i did i couldn't fix it. On this forum i got an advice from AKStew that the problem might be mechanical and not electrical. That lead me back to the throttle cable again and i started to check on that. I checked that the throttle cable and housing moved freely and lubricated the cable. Then I opened the throttle case cover. I checked that the throttle wheel moved freely and that it made contact with the stop screw when the throttle lever was released, it did. I lubricated the wheel and then I got an idea. Instead of putting everything back together I only put one of the three screws that hold the throttle case cover back, thinking if I leave it with one screw only I can easily check the position of the throttle wheel when the idle get stuck. I went out driving and after an hour or so it happened, the idle got stuck at 1600 rpm. I forced the neutral in and jumped of the machine and unscrewed the single screw that held the case cover. Inside I could see that the throttle wheel made contact with the stop screw. Everything looked fine but then with a screwdriver I manually pushed the throttle wheel back against the stop screw. I heard the idle decrease just a few rpm, I pushed harder and then whoops the idle sunk to correct level 1180 rpm and stayed there also when I stopped pushing on the wheel. So the stop screw was too high. Now, in Polaris workshop manuals there are plenty of warnings about adjusting the stop screw yourself. According to the manuals the stop screw is set at the factory and should not be adjusted after that. So instead of adjusting it i cleaned the entire throttle body with break cleaner thinking that dirt might prevent the butterfly to close completely. That did not help. So despite the warnings about the stop screw i decided to turn it down one millimeter. And after that the problem disappeared.

Everything took six months of, fixing, thinking and testing before all problems were solved. Its worth to mention that i know of one other identical machine and year (Polaris Sportsman 500 EFI year 2007) that had the same problem with the stop screw, so maybe this is a common problem of that model and year.

Thanks for advices i got in this forum during the process!

/Jonas
 

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Nice write up! I am sure this will help somebody down the road resolve a similar issue.
 

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Great news you got it fixed and this write-up will surely help others.

Stew
 

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Gonna give this a shot...... ironically, I also bought a 2007 Sportsman 500 EFI in November of 2011 and having the same issues (only difference is that mine is an X2 Deluxe)

The link to the TPS test connector is broken, where can I find it?

Thanks!
 

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holy crap... 51 bucks for that?

I'll just test the..... yellow wire I believe, to ground and see what the voltage is. I fixed the stalling issue, now it just wont idle if the motor is cold, I have to keep my thumb on the gas and the cable adjuster is pretty much all that controls the idle now, not the tps
 

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This is a description about how idle problems were solved on a Polaris Sportsman 500 EFI 2007. I hope this post can be helpful to members of the forum and others.

I bought a used Polaris Sportsman 500 EFI year 2007 in November 2011. It only had 6 hours on the meter an had obviously been sitting a lot. After i had run it for a few hours i started to have problems with the idle. The problems can be divided into three.

1. Sometimes the machine did not want to idle at all. It died when i released the throttle, sometimes this happened immediately or after a few seconds of idle.

2. Sometimes the idle stuck at around 1600 rpm and did not come down to correct level about 1140 rpm.

3. When it did idle the idle wasn't very stabile. It went up and down between 1100 – 1500 rpm.

Problem number 1 was quite easy to fix. The throttle cable tension was to loose causing the contacts in the ETC switch to make contact. This is a safety mechanism that prevents the engine to run if the cable is stuck with the throttle in open position. But this also happens if the cable tension is to loose. I tightened the cable tension and problem number 1 was fixed.

Problem number 2 and 3 were more difficult to solve. I checked all wiring from the IAC, the TPS and the MAP sensor to the ECU. Found that the insulation on one of the cables from the TPS was broken. Ok here we have it i thought. I isolated the wire but the problems remained. Then i tried cleaning the IAC and the MAP sensor and all connectors. It did not help. I bought new (used) IAC and MAP sensor. No luck. Finally i bought the TPS test connector https://polaris.spx.com/Detail.aspx?id=182. With this tester and a multimeter i could se that there were jumps in the volts on my TPS when i moved the throttle from closed to wide open. I bought a new (used) TPS and problem number 3 was solved. The idle became stabile at around 1180 rpm.

Problem number 2 still remained unsolved and no matter what i did i couldn't fix it. On this forum i got an advice from AKStew that the problem might be mechanical and not electrical. That lead me back to the throttle cable again and i started to check on that. I checked that the throttle cable and housing moved freely and lubricated the cable. Then I opened the throttle case cover. I checked that the throttle wheel moved freely and that it made contact with the stop screw when the throttle lever was released, it did. I lubricated the wheel and then I got an idea. Instead of putting everything back together I only put one of the three screws that hold the throttle case cover back, thinking if I leave it with one screw only I can easily check the position of the throttle wheel when the idle get stuck. I went out driving and after an hour or so it happened, the idle got stuck at 1600 rpm. I forced the neutral in and jumped of the machine and unscrewed the single screw that held the case cover. Inside I could see that the throttle wheel made contact with the stop screw. Everything looked fine but then with a screwdriver I manually pushed the throttle wheel back against the stop screw. I heard the idle decrease just a few rpm, I pushed harder and then whoops the idle sunk to correct level 1180 rpm and stayed there also when I stopped pushing on the wheel. So the stop screw was too high. Now, in Polaris workshop manuals there are plenty of warnings about adjusting the stop screw yourself. According to the manuals the stop screw is set at the factory and should not be adjusted after that. So instead of adjusting it i cleaned the entire throttle body with break cleaner thinking that dirt might prevent the butterfly to close completely. That did not help. So despite the warnings about the stop screw i decided to turn it down one millimeter. And after that the problem disappeared.

Everything took six months of, fixing, thinking and testing before all problems were solved. Its worth to mention that i know of one other identical machine and year (Polaris Sportsman 500 EFI year 2007) that had the same problem with the stop screw, so maybe this is a common problem of that model and year.

Thanks for advices i got in this forum during the process!

/Jonas

This thread is pretty old now, but I have an 06 sportsman 500EFI. My grandpa bought it in 08 and barely used it. He gave it to me in '19 after two years of sitting. It fired right up and ran fine for about 6 months. Worked great all through hunting season, then BAM! It died on me when I was getting a new hunting property ready in March. It was sitting there idling, then all of the sudden sputtered out. Wouldn't start back up unless I was giving it gas. Then it would run really erratic and stall after 40-50 yards. Luckily, after start-stop a half dozen times, I got it back to the truck and to the house. I spent hours and hours messing with it. New oil/filter, spark plug, fuel injector, breather lines, fuel filter, checked the sensors, etc. Finally had my father in-law, who has been a mechanic for 40+ years help me figure it out. We messed with the TPS and after a little adjusting it idled and stayed on, but was idling at a high RPM.. I ultimately set the TPS back to where it originally was, made a few slight adjustments with the throttle stop screw until it fired up and idled correctly. If you look in the throttle body, the butterfly valve should BARELY be open. My screw had just came out slightly with hardcore riding over that 6 months and the air-fuel ratio was off and stalling out the motor. It was backfiring, running erratic, wouldn't stay on. Now it works fine.
 

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Thanks a bunch for the write up, I’m commenting so I don’t lose this thread. I may need it in the future lol
 

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I bought Sportsman 500 EFI -08 and it has also idle problems. Sometimes idles, sometimes not at all.
I thought it would be simple fix...
1. i checked "dead mans switch" on handlebar. there was 2-3mm gap between connectors. I cleaned it and checked movement.
2. i checked map-, tps- and fev other connectors and cleaned those
3. i checked map sensor wiring till main harness. I found that protective cover of 2 wires was broken. I fixed those and for five minutes it worked well till it stalled again.
4. i checked map sensors connector with resistance meter and found out that there were resistance between orange and purple wire. Is that ok? I don´t rememeber what was value, 0,2 something.
5. i started to tear down more wire harness and for that almost all body parts had to take off too. So far no other broken wires has came up.
6. What next?
 

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2008 800 ho efi, 2019 850 SP premium
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I bought Sportsman 500 EFI -08 and it has also idle problems. Sometimes idles, sometimes not at all.
I thought it would be simple fix...
1. i checked "dead mans switch" on handlebar. there was 2-3mm gap between connectors. I cleaned it and checked movement.
2. i checked map-, tps- and fev other connectors and cleaned those
3. i checked map sensor wiring till main harness. I found that protective cover of 2 wires was broken. I fixed those and for five minutes it worked well till it stalled again.
4. i checked map sensors connector with resistance meter and found out that there were resistance between orange and purple wire. Is that ok? I don´t rememeber what was value, 0,2 something.
5. i started to tear down more wire harness and for that almost all body parts had to take off too. So far no other broken wires has came up.
6. What next?
Font Window Pattern Screenshot Automotive exterior
to the forum
Gas Font Automotive lighting Ball Vehicle registration plate
 

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I bought Sportsman 500 EFI -08 and it has also idle problems. Sometimes idles, sometimes not at all.
I thought it would be simple fix...
1. i checked "dead mans switch" on handlebar. there was 2-3mm gap between connectors. I cleaned it and checked movement.
2. i checked map-, tps- and fev other connectors and cleaned those
3. i checked map sensor wiring till main harness. I found that protective cover of 2 wires was broken. I fixed those and for five minutes it worked well till it stalled again.
4. i checked map sensors connector with resistance meter and found out that there were resistance between orange and purple wire. Is that ok? I don´t rememeber what was value, 0,2 something.
5. i started to tear down more wire harness and for that almost all body parts had to take off too. So far no other broken wires has came up.
6. What next?
Sent you the manual - server rejected [email protected]
 

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2008 800 ho efi, 2019 850 SP premium
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15,182 Posts

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2008 800 ho efi, 2019 850 SP premium
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