Sportsman 800EFI

I have an 05 Sportsman 800EFI.  When it gets hot, it shuts down.  (Almost like it vapor locks).  Wait 10-15 mins, and it will fire up and run fine.  Any suggestions?  

it sounds like the cdi box is getting hot and shutting the atv down.

there is a recall for your atv for a defective ECM.

the recall says that they fail and overheat and even could possibly cause a fire.

but it makes sense that this is the problem, and Polaris would be reluctant to replace it under the recall being it is 3 years old.  
Keep it RUBBER SIDE DOWN!!

wE HAVE A 2006 pOLARIS 800efi AND IT HAS THE SAME PROBLEM SEVERAL TIMES IT HAS HAPPENED AND pOLARIS CANNOT SEEM TO FIND THE PROBLEM.WE HAVE CHANGED THE ELECTRONIC BOX STILL DOING IT ALSO THE FEUL PUMP ANANOTHER TIME THEY TOLD ME IT WAS A LOOSE WIRE ANY EXCUSE TO GET RID OF ME VERY DISAPPOINTED WITH THIS ATV.  

when it shuts down does it still turn over?

if so, turn it over after it shuts down and see if it is firing at the spark plug.

if not firing at the spark plug then it could be the stator or another bad cdi box.
it doesn't sound like a wire loose.
it sounds like the dealer is giving you any excuse they can to get you out the door.

especially with the ecm being defective and under recall.

ahh yes, dissappointment, i see alot of dissappointed Polaris owners.
I have lowered my labor rates for polaris machines because it can get really expensive to continually repair a polaris, Most wont take them to the dealer after the dealer refuses to honor the warranty, so i see alot of Polaris' mistakes, defects and general screw ups.
and it is frustrating when the customer has to spend money to make the same repair in the same season especially when it should have covered under the warranty.

I have fought with Polaris many times trying to get Polaris to warranty defective parts for my customers. time and time again they refuse to admit that the part could even go bad.
I have put many oem cdi boxes and stators on Polaris machines for my customers and had them go bad the next day, and have even bought them from the dealer and checked them with a meter before i put them on and they were bad without being installed.
Still... the dealer acts like they are bullet proof and can't possibly go bad. if you can buy an aftermarket replacement part, i suggest you do so, they work so much better than the oem in alot of cases.

I have heard the same story a million times,
the customer takes it to polaris they say it's fixed under warranty, customer gets it home and it's not or it breaks down again soon after getting it home.
then the customer takes it back to the dealer where the dealer blames the customer, and refuses to warranty anymore parts.
then they come to me to get it fixed.
I fix it and tell them it's likely you'll be back for the same problem.

most times they end up selling their polaris and buying something better.


It's a shame that so many Polaris customers' have to shell out so much money in repairs and Polaris doesn't seem to care.  
Keep it RUBBER SIDE DOWN!!

The problem is consistant among the 700EFI and 800EFI twins.  The fuel tank and fuel line is getting hot and vaporizing the fuel.  The tanks and lines sit right on top of a hot engine and exhaust which literally causes the fuel to boil in the tank and line causing vaporization.  The heat shielding on the tank is totally inadequate for these ATVs.  I completely lined the bottom of my tank with reflective insulated aluminum insulation and aluminum duct tape.  It seems to be working for me.

This is yet another quality issue with Polaris Sportsman twins that Polaris refuses to recognize.  

yea i have 800 it *** the starter gear big dollars .drop the touth in to the
stator fried it  more big dollars . be side all the plastic are melted .
tps sensor *** it self more big dollars. and now ecm fried .extrem amounts of dollars . dearlers told it was al my falt .now they have shut shop.so now no one to
fix the peice ***  and get this its only got 48 hours on it  IT IS THE BIGGEST
PICE OF JUNK I HAVE EVER SEAN  THANKS POLARIS YOU HAVE RIP ME OF BLIND '