'94 Polaris 300 Reverse Problem

[Big-Al]

I just picked up a second ATV that would not idle. I adjusted the screw on the right side of the carb counterclockwise and the machine now idles but dies immediately when put in reverse unless the reverse button is depressed. I am familiar with the polaris reverse button, but have never seen that machine kill(only run poorly) if the button is not depressed. The machine runs just fine otherwise. Any suggestions?

[Roofer]

It's the shift lever not making contact in reverse. Very common problem with the older Polaris's. You can bypass the reverse over-ride and possibly fix the problem. I can try to find the instructions for this, if you want.

You could also take apart the box that the shift lever goes to and add a shim to make contact. You will see what I mean when you take it apart. I haven't had luck with this, but some say it works. Another alternative is to buy a new shifter. It comes with a new box and is updated, but I think it is a little pricey.

Hope this helps.

[Roofer]

You could also try to adjust the linkage to the shifter. It's a bit of a pain, but sometimes that works too. If you do this, just make sure you are adjusted properly for all gears because if too far toward reverse, you won't have low range.

[Big-Al]

Thanks Roofer, I will take a look at that. I haven't nocked a wire loose on the transmisssion or something have I?

[Roofer]

Nope, it's just a contact that eventually works loose and needs to be shimmed. That is, if I'm correct in my thinking from my previous Polaris's.

[IndyEFI500]

Check the screws on top of the shift linkage. One of mine used to come loose. Tighten and good for a while longer. Loc-tite didn't seem to help at all.

[NAMASafetyDirector]

Big-Al- you may also want to take the top off of the throttle block. The Polaris has an ETC (electronic throttle control) switch on there that sometimes sticks for one reason or another. If it is stuck it automaticly kills the engine as if the throttle is stuck wide open. The Polaris snomobiles all have a similar feature on the thumb throttle. It's the little button on the throttle block when you pull the thottle open. On the atv's it's right underneath the cap on the throttle. Might be worth checking if you have trouble solving the problem. It's just on there to prevent the thing from blasting off if the throttle happens to get stuck wide open. Good Luck!

[ratmn218]

have the same machine, same problem, works right sometimes other times i have to hold the overide button in.wish i knew what wires to cut, or to wire together to override the switch. for some reason that machine keeps pumping oil mist out of transmission breather hose? any simuler problems on yours?

[huntingislife]

A far as the overriding a faulty rev limiter or just doing the reverse override it is pretty simple:

Check the wires going into the CDI. You are looking for a black wire going from the speed limiter to the CDI unit. Disconnect the black wire, and see if it runs. If it does, the rev limiter is bad, or is somehow getting a bad signal to kill the engine from somewhere.

You won't damage anything by running the machine with the black wire disconnected (be sure to tape it up good) but realize you are by-passing a safety measure, and will be able to go about 40 MPH in reverse if you hold the throttle pegged, so USE CAUTION if doing that, and remember you are responsible for not backing up too fast.

[Big-Al]

I tried all the original suggestions with no luck. I will try the new suggestions when I get a chance. And ratmn218 I don't have an oil mist coming out of the breather.

[ratmn218]

on the left side of machine under front side cover there is a circut board assembly? with bunches of wires plugged in it. top left are black wires, unplug and tape up second black wire down from the top. worked for me, good luck.

[Big-Al]

NAMASafetyDirector- Checked out the ETC and everything seemed in order. Figured I'd try that first since it seemed easiest.

ratmn218- Tried your fix next. The good news is that when I disconnected the wire that you did, it ran great in reverse. The bad news is it would not shut off, with the key or the kill switch. I reconnected the second wire down and disconnected the top wire and now is functioned great.

huntingislife - does this mean that my rev limiter is bad? I probably won't replace it, unless I sell the machine, which I doubt. It is like a brand new machine to me even though it is a 94. I think they are great machines for transportation only, but not for a work machine. I've got a Honda for that.

Thanks all for the responses. She is running great now.

[ratmn218]

opposite here top black wire disconected rev liniter but switch wouldnt work or kill switch ,just glad we got it figured out.thanks,95 must be a little different.

[huntingislife]

If it worked after you disconnected the wire then the rev limiter is bad. I wouldnt bother replacing it ($65). It will be fine without it. Glad to hear its working now.