My 2005 Polaris 500 Died Doen t Turn on Again

The Polaris Sportsman 500 is a serious trail quad, offering lots of power and practiced traction. But there'south one effect preventing y'all from riding this ambitious 4×4 – it dies when accelerating. You may take tried everything, such as replacing the carb or even the entire engine. And so, you may be wondering why your Polaris Sportsman 500 dies when accelerating.

The reason the Polaris Sportsman 500 dies when accelerating often comes from the CDI box, which is used to pass electrical current to the spark plug and ignite the engine. Replacing information technology with a Polaris CDI box should fix the problem. If non, bank check other parts of the quad.

Nigh people would offset think the issue relates to the carburetor, which controls fuel and air inbound a motor. Nevertheless, many have discovered the crusade of the problem to exist electrical – more than specifically, the CDI box.

Polaris Sportsman 500 Dies When Accelerating

This can be a frustrating upshot, especially if yous don't know why information technology happens. Keep reading to learn more nigh this trouble, and other things you can attempt if replacing the CDI box doesn't help.

What Is Inside a CDI Box?

A typical Capacitor Discharge Ignition box consists of a small transformer, a triggering circuit, a charging circuit, and the main capacitor. The rectifier institute within the charging circuit stops capacitor-discharge before the moment of ignition.

Typically, it controls the factory safety kill switches, timing, the spark, and the rev limiter. Depending on the ATV'due south make and model, the CDI box configuration can differ and control other things aside from what was mentioned.

What Are the Symptoms of Bad Polaris CDI Box?

When a Polaris Sportsman 500 idles but dies, information technology can point to different things, such as misfires, starting problems, rough running, and fifty-fifty a stalling motor. The below signs can help you determine if the problem is from the CDI box:

A bad CDI won't fire at all since everything goes through the box to fire the motor.
Ignition leads will shorten if yous spray a canteen of water on them.
Frayed wires or loose spade connectors can typically exist remedied with a little pinch and some dielectric grease. If this doesn't change anything, and then consider it a symptom.
A cooked battery can ordinarily be traced dorsum to a defective rectifier/regulator.
Carboned plugs alluvion the carburetor and point towards a faulty CDI box.
Testing your ignition coils with a multimeter gives results outside of the secondary resistance parameters indicated in your manufacturer specifications.

Causes of Restricted Acceleration

While the following unremarkably crusade the Polaris Sportsman 500 to die when accelerating, these should not always be the first prepare of things to inspect. Still, understanding where these problems come up from and how to resolve them will non only salvage you money on repairs simply also valuable time:

1. Stator or Coil Failures

A bad source roll in the stator causes the CDI to stop running. A DC conversion kit is a adept replacement for the stock CDI box equally it bypasses the defective source coil. However, symptoms for this cause unremarkably overlap with electrical wiring or engine compression problems. The best way to find the culprit is to run tests and single out the likely cause one at a time – starting with the compression test, which is the easiest, followed past wiring inspection.

For engine compression, perform an initial test when the engine is cold. When it dies out a 2nd time, test it immediately again. Compare the two results. If the second is significantly lower than the first, you might have institute your trouble. If this checks out, inspect wiring harnesses that might contact hot surfaces similar the frazzle. Also, check if the cylinder head has non been melted or chaffed in any way.

2. Carburetor

The carb is unremarkably the kickoff thing owners suspect as the main cause. Symptoms can get severe to where the carb would only run with the choke on/off or with carb cleaner sprayed downwardly its throat. Some would often jump into replacing bolts, bushings, and the safety diaphragm at the first sign of a carb trouble. They would often forget about giving it a new carb kit when cleaning it out. The needle and seat alignment are often disregarded too, which is the only reason for the impeded throttle response of your Polaris Sportsman.

Note that for Polaris 500s with CV carbs, you accept to maintain a sure corporeality of vacuum to operate the slide properly. This necessitates running a hat and changing the jets. These carbs are very sensitive to airbox changes. Running a new carb kit and modded airbox may take some testing to get information technology dialed in.

Similarly, information technology is crucial for ATVs with Keihin carburetors that you bank check the valve clearances, as they cause the aforementioned symptoms as those of Sportsman 500s with CV carbs. Inspect the secondary air intake port at the venturi – the small non-replaceable jet embedded in the passageway. Disassemble the carb, spray cleaner through the passage, and then have a pocket-sized-diameter wire and run it through. Blow through with compressed air to consummate your thorough cleaning and repeat from both directions of the valve clearance.

three. Camshaft & Exhaust Lobe

The exhaust lobe on the cam is prone to wear if you neglect scheduled oil changes. In extreme cases, the exhaust lobe is so worn-out that a rebuild is needed. Interestingly, the exhaust lobe wearing out on the camshaft is responsible for the restricted acceleration of the Polaris 500 90% of the time.

If the cam turns out to be the problem, yous volition need to supersede the rocker arms. As well, remember that this troubleshooting footstep is only necessary if both the CDI and carburetor check out. It is also best performed past a professional person as the timing procedures are meticulously done.

Other Things to Bank check if Your Polaris Sportsman 500 Dies When Accelerating

one. Fuel

Insufficient fuel may be a cause of your Polaris Sportsman dying when accelerating. If yous suspect this, refill the gas tank and ensure that you plough the bicycle key on at to the lowest degree 3 times before restarting the engine. Additionally, bank check that the fuel is not fix to "reserve."

While checking the fuel quantity, inspect that in that location are no chock-full or damaged fuel vents impeding the menses of fluid and that the fuel itself is uniform with your ATV and not watered down. Drain and replace the fuel inside your gas tank if found to be incorrect.

2. Restricted Airflow

Limited airflow is some other cause of ATV bogs when giving gas. Unlike the other symptoms, this is easier to pinpoint equally the auto revs and idles only fine when yous let off the gas, or your ATV will be running either too lean or too rich.

Commonly, a dirty air filter or carburetor, stuck-on-close choke, plugged master jet, junk-filled float bowl, misadjusted valves, or air intake tube blockage is responsible for this brake. Resolving whatsoever of these causes will vary depending on the year of your Polaris Sportsman 500.

3. Parts Malfunction

If your ATV bogs down when applying throttle, you likely accept defective spark plug wires, non-working reverse speed limiter, electronic throttle control glitches, and sometimes even a bent rocker arm. A seasoned mechanic can opt to supplant lacking parts with OEM ones and resolve the consequence themselves. Otherwise, these mechanical failures merit a visit to a Polaris dealer to administrate repairs.

Identifying why your Polaris Sportsman 500 dies when accelerating tin be catchy and should not exist confused with other known issues for the quad. Some of these common problems include the vehicle not turning over, engine non starting, machine backfiring, stalling, misfiring, and the Sportsman overheating.

Always refer to your possessor's manual for guidance and footstep-past-step procedures on troubleshooting specific Polaris ATV issues.

4. Throttle Cable

Carbureted Polaris Sportsman 500 ATVs specifically take what you lot call an ETC or Electronic Throttle Control. The two metallic contacts of this associates should never touch. Otherwise, it volition cause the car to die. If you figure out that this is the crusade of your quad stalling or dying during acceleration, you need a throttle cable adjustment.

When adjusting, brand sure to route the throttle cablevision correctly along the channel institute on the side of the gas tank. Check that the throttle channel is not kinked or obstructed in whatsoever style.

5. Cleanliness

Keeping your quad make clean non only make it last longer, but it as well helps with your vehicle's proper function. In some instances, your Polaris Sportsman 500 dies when accelerating due to dirty spark plugs and debris in the fuel vents or the radiator, non because these parts are faulty.

Regular cleaning of your quad inside and out goes a long way in preserving how your wheeler operates. If certain parts are across filthy and cannot be salvaged via cleaning, it's time to supplant them.

EFI Loss of Spark

For fuel-injected Sportsman 500s, you need to check the map, crank, or TPS sensor harness wires to see if wiring pulled out from the sensor connectors causes the problem. These tiny sensors are bad at shorting out against the starter or engine instance. They also do non need bare spots to exist defective as their soft spots internally make them prone to issues.

You should also maintain fuel pressure at 39 psi. If you go lower or erratic pressure readings, and then it could point to a fuel pump problem. These two checks are necessary on summit of troubleshooting that you would normally do for a carbureted Polaris 500.

Polaris CDI Installation

This video demonstrates the proper installation of a Polaris stator and CDI ignition kit for a 1998 Polaris Sportsman 500.

How to install the CDI box:

Remove the bracket (Torx T25).
Disconnect the following plugs from the erstwhile CDI box:
- 2 pins plug (pickup coil)
- 3 pins plug (source curl)
- Blueish/white wire (ignition coil)
- Blackness wire (kill switch)
- Chocolate-brown wire (footing)
Connect the new DC CDI box to their corresponding plugs, as seen in the video.

The Polaris CDI kit is a plug-and-play unit that should connect to the same plugs that disconnect from the stock CDI (except for the orange wire, the hot switched wire). For DC conversion kits, this orangish wire connects to the Polaris Sportsman 500 battery via a hot wire last where the box volition draw power from instead of the stator.

The hot wire terminals on the '98 model are located on either side of the two open terminals beside the switch peak excursion. Y'all tin can as well crimp the bare stop of the orangish wire with a female person spade tuner and then you can press it into the junction board, tucking it neatly into place.

Installing a DC conversion upgrade kit is fairly straightforward. Choosing to upgrade to a DC ignition system is better than a conventional CDI box that requires a working source coil for two reasons:

Information technology will work even if your source coil is defective.
Cold-starting volition be easier.

For a '98 Sportsman, yous can mount your replacement CDI box on the crossbar in the engine compartment using a cable tie. Accept note as well that only an OEM Polaris CDI box replacement resolves the loss of power in sure cases.

Conclusion – Polaris Sportsman 500 Dies When Accelerating

Your Polaris Sportsman 500 dying out during dispatch tin can be frustrating, especially if you lot do non know why it occurs. The problem normally traces dorsum to the CDI box, making cut-off throttle response easier to resolve and manage.

If the CDI box doesn't demand replacement, verify if you take spare parts that you can use to replace current ones. Regularly cleaning your carburetor and existence on top of your scheduled oil alter also practice wonders for your quad. With restricted acceleration at bay, yous tin fully enjoy your Polaris Sportsman 500.

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Source: https://offroadingpro.com/polaris-sportsman-500-dies-when-accelerating/