Headache growing- 2012 Pro cutting out

[8emup]

My 2012 hasn't run correctly in about six weeks. It's been to the dealer multiple times. It shows no codes what so ever. They've taken it out on a couple rides and it never acts up on them. The TPS has been changed. It's an older TPS because Polaris has no availability on new ones. Whatever the problem still exists. The biggest bummer the season is about to end and this isn't resolved and do we even have enough season left to get this resolved or do I begin next year with this headache.

The problem when I stab the throttle it cuts out. I road it again on Thursday and for the first 25 miles it ran near perfect just a couple of hesitations. The next 25 miles every time I grabbed the throttle a hesitation. If I grab the throttle very smooth and easy it's ok. Once I start grabbing it a little quicker it bogs and runs horrible. Earlier in the day it was no problem grabbing the throttle quickly but as the day went on problem became very constant.

So at this point please throw any and every idea at me. What's going on???

The dealer will sort it but it doesn't sound like Polaris is coming up with many helpful ideas as they've been consulted multiply times at this point.

As great as the sled side hills and handles it's worthless if the motor runs like hell.

 

[sledstew]

here is the problems Ive seen that did the same as you have been saying:
Kill switch (intermittent issues)
Speed sensor wires(specifically the plug gets moisture)
Throttle safety switch is bad

hope this helps
Jake

 

[19 Hundo]

I feel your pain....mine just went back to the dealer after yesterdays bogs. At about 4500 rpm I would grab a handful of throttle and it fell on its face for a second then go. Oh and also blew the chain case up yesterday and my clutch sping is about to break looking at the wear marks on it and the sled only has 180 miles on it.

I want my 900 back, never had a single problem with it

 

[AdrenalineAddict]

This might sound a little to simple and maybe you have tried it. Have you taken all the slack out of the throttle with the inline mounted cable tightener. It's about 12" to 16" from the flipper. Everytime I can see or feel just .010" or .020" of play in my cable at the flipper my sled does the same thing, when I tighten it up to nearly zero it runs perfect. A friend of mine had the same issue with the same result.

 

[rugbynitro]

I am having the same problem as you to a lesser degree and not every day. Once it starts, it's a problem the rest of the day.

Had the dealer make all the above changes and put dielectric grease on all of the connections and it has improved but still there on occasion.

The only thing left to is replace the entire wiring harness, which Polaris has agreed to do. My dealer has done another sled as well. Problem is, all of the complete wiring harnesses are back ordered (I wonder why?)

For the most part you have a great engine but the wiring harness is made in China and NFG. I strongly suspect it's causing a lot of our problems.

Good Luck! Remember the second year Polaristar warranty will not cover electrical problems.

 

[TCPSOUTH]

Check your spark plug wires and replace your spark plug caps. Make sure your throttle safety switch isn't sticking, they usually have alot of grease on them from the factory. Had same issues last year and this worked for me. Good luck!

 

[Murph]

Sorry for the headache.

Unfortunately, some dealer mechanics rely too much on digital wrench and not enough on their own troubleshooting and deductive reasoning skills.

Yes, the sleds have gotten more complex-- but not so much that we can't still figure out what the issues are without just throwing parts at them.

This is not directed at the OP or anyone else on this forum but I'm getting pretty tired of reading "Polaris isn't being much help". Dealer mechanics should have the skills to troubleshoot.

Troubleshooting is time consuming (why many dealers/ mechanics don't want to do it), but it isn't rocket science.
1.Replicate the bog-- make note of engine temp, ambient temp, engine load, throttle position, rpm, is the sled wet inside or dry, beginning of ride middle of ride end of ride, during a bump section, after a landing, etc.
2. determine its cause
3. exchange part
4. Try and replicate bog, if it's fixed great, if not move on to the next idea
5. Repeat

Similar running problems discovered on this forum.

1. VES system- sticking exhaust valves, plugged hoses, bad VES solenoid
2. TSS switch - can be intermittent due to body position on sled. My 2012 would fail consistently for me but not a tech due to how I applied throttle. I taped switch closed just like I did on my 2011. You cannot just cut the wires, the switch is based on resistances.
3. Throttle free play-- sounds silly but it has caused as many running issues as anything else
4. Exhaust temperature sensor
5. TPS-- moisture getting inside the boot? A lot of shops just like to thrw a new TPS on the sled. If the TPS is fine and it is a moisture problem, the new TPS will "fail" same as the old. The mechanic will then tell you, "It's not the TPS, I changed it out and it had no effect" or you think it's fixed, then it develops moisture again. You think it's still doing it and we just changed the TPS, must be something else. Mine likes to develop condensation inside it even when there is no snow/ moisture on the outside of it-- symptom was always the same refusal to go into reverse
6. Wire harness grounding out somewhere- have you replaced your bumper? Reports of bad grounding where all the ground wires come together a the bumper mount
7. Loose ECU connection
8. loose stator wire in the housing itself
9. Spark plugs, wires, loose connections, intermittent grounding


Good luck.

 

[pura vida]

interesting thread. i'm also have a issue with the sled cutting out. my starts out by cutting out/stumbling on extended climbs. then it will idle and be ok wfo but the mag cylinder completely drop out in the mid range. then the mag side will foul the plug and completely drop the cylinder. replace the plug and it runs good for awhile. took it to the dealer. they replaced the plugs and said i was good to go. i don't buy it (i'm dumb, but not that dumb. and have already replaced plugs a couple of times) so i will trouble shoot it myself and take it back in when i have more ideas. testing starts today.

pv

 

[danjpohl]

Only time mine bogged this year I believe was from moisture. I had snow coming up over the windshield then stopped to dig someone else out. Right after I got going it bogged real bad until I had ran 15 minutes or so then it never did it again. The guide said he had seen that multiple times.

 

[freerideordie]

interesting thread. i'm also have a issue with the sled cutting out. my starts out by cutting out/stumbling on extended climbs. then it will idle and be ok wfo but the mag cylinder completely drop out in the mid range. then the mag side will foul the plug and completely drop the cylinder. replace the plug and it runs good for awhile. took it to the dealer. they replaced the plugs and said i was good to go. i don't buy it (i'm dumb, but not that dumb. and have already replaced plugs a couple of times) so i will trouble shoot it myself and take it back in when i have more ideas. testing starts today.

pv

this sounds like a leaking injector... just delt with the same issue

 

[TAE]

My 2012 hasn't run correctly in about six weeks. It's been to the dealer multiple times. It shows no codes what so ever. They've taken it out on a couple rides and it never acts up on them. The TPS has been changed. It's an older TPS because Polaris has no availability on new ones. Whatever the problem still exists. The biggest bummer the season is about to end and this isn't resolved and do we even have enough season left to get this resolved or do I begin next year with this headache.

The problem when I stab the throttle it cuts out. I road it again on Thursday and for the first 25 miles it ran near perfect just a couple of hesitations. The next 25 miles every time I grabbed the throttle a hesitation. If I grab the throttle very smooth and easy it's ok. Once I start grabbing it a little quicker it bogs and runs horrible. Earlier in the day it was no problem grabbing the throttle quickly but as the day went on problem became very constant.

So at this point please throw any and every idea at me. What's going on???

The dealer will sort it but it doesn't sound like Polaris is coming up with many helpful ideas as they've been consulted multiply times at this point.

As great as the sled side hills and handles it's worthless if the motor runs like hell.

sounds just like mine and they finally changed out the injectors and runs great now. also might want to change out the crappy plastic fittings on the VES system as they can crack and break can cause sled to cut out above ~7000 rpm.

 

[black swan]

does anyone think this is map related?....mine has done this 3x now ride in very warm temps at 11k.....runs fine till temps hit 50+deg or higher, tried new plugs and both fuel resistors.

dealer replaced TSS and throttle block to currently part#...and found tps alignment to be fine. No codes
sled stumbles off idle and at WOT, if you ease thru the throttle postions you can avoid the bog.

let sled cool down for 1hr, runs fine...till it get hot.
Below 40deg sled run fine.

 

[8emup]

Could it really have been as simple as throttle cable tension? Five turns tighter and the sled won't start. Backed it off two turns and the sled ran perfect for the twenty miles I rode today. I grabbed a hand full of throttle probably 50 times and no bog. I hope that was the problem but as intermittent as it's been who's knows. If the snow sticks around I'll have to ride it some more.

On another note Wolf Creek Pass access here in utah is going away quickly lots of bare pavement.

 

[Luke45]

Same problem with me... I finally just got it done and running so much better now... Mine was the injectors, did you check that out yet?

 

[gman086]

Could it really have been as simple as throttle cable tension? Five turns tighter and the sled won't start. Backed it off two turns and the sled ran perfect for the twenty miles I rode today. I grabbed a hand full of throttle probably 50 times and no bog. I hope that was the problem but as intermittent as it's been who's knows. If the snow sticks around I'll have to ride it some more.

On another note Wolf Creek Pass access here in utah is going away quickly lots of bare pavement.

YUP - that's what it was on mine along with not having quite enough clutch weight. Was doing exactly what yours was - bogging only when hammering down the throttle.

Have FUN!

G MAN

 

[winter brew]

Sounds like you found your issue, but just to add to the list of possibilities for others with similar problems.... We have found taillight wires grounding out and causing a bog, also the ground wires at the left front bumper bolt being corroded (seems to have corrosion starting even when new), cleaned up and this eliminated a occasional bog, high idle and no reverse.

 

[flying frenchman]

My 2011 still does this. Sure pisses me off. I've tried everything.
Fun sled but sure sucks when I get a surprise once in a while when you do need your sled to jump something and it falls flat on it's face. Same thing happens while zipping through the trees when your off and on the throttle. My carburated sleds never acted like this, they just ran flawless.
Good thing we pay big money for these sleds.

 

[Dootimes2]

Mine was tps and wifes was tps and injectors. Both 2012's. I also keep an eye on throttle cable play. It is so simple I think the techs over look it. They should'nt but some do.

 

[pura vida]

my issue was not injectors. my was self induced. unplugged the pcV and ran all day without a single issue.

pv

 

[8emup]

Throttle cable tension I think it was that simple. 60 miles today never missed a beat. Thanks for the help!