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Fyi - mine had 2 batteries. Switched them out to 1 bigger utility tractor/mower battery. Never had an issue starting, plus a lot cheaper than the stock mc batteries.

I was going to say the same thing as @Frank Angerano check the float, almost sounds like it's fuel starved on 3/4 throttle. Sometimes the pins hang up although you mentioned its a new car, so it shouldn't.

Got it to run today, just needed the injector cam/throttle linkage freed up... Got it in place, what a pita working the engine/transmission in that hole... I'll have to move the two front small suports a little forward and move the mounting brackets a little but everything should work out well... Also will have to change the drive belt to be a little longer. Dayco has a wonderful page that list lengths/widths if anyone ever needs it.... Maybe even do a new thread once its complete... But its not like your going to find a lot of Polaris diesel threads on here...

I bought all new cables for my YFM225 Moto-4 a few months ago. They can be purchased from either the Rocky Mountain ATV website or from Babbitt's website. You will find them listed under the OEM Parts section: CABLE, BRAKE 2HT-26361-00-00 And are about $33 each.

Hey gator man. Are the new jets oem parts or aftermarket? The jets as far as I know are seated until tight and just a small bit of pressure to make sure they will not come loose. Now as far as adjustment I believe there should be only two screws for adjustment. 1 is the air/fuel mixture screw. This should be turned until snug and then bring it out about 2 and 1/2 turns and leave it there. The next one is the idle screw and that should be adjusted once the bike is running. The air/fuel screw should be slightly adjusted once the bike is running maybe a quarter turn more out or in and can be determined after you take a ride and see how she runs. Was the carb in bad shape and dirty? Also with regard to the jets and mixture screw were the springs and o ring in place on the air/fuel screw ?

I'm in the middle of putting a 99 diesel into a 2009 frame.... I bought the engine (nothing with it) by mistake (thought it was a different engine till it was too late to back out) and it sat here... a week ago I found a free to me 2009 500 with a locked up engine... so far everything will be simple to swap out... mounts are in the same places, hoses hook up the same, and the clutch will swap as well. Its good to read you like yours, I'll try to keep you updated on how this one turns out.

I've seen people get on and ride it like they stole it when they have never rode one before... It didn't end well. Where I live the hills can be so steep you will end up dead quick, so I'll be slow and slow on mine...

it ended up being air trapped in fuel lines to and from pump. I had forgotten I had put the valve on reserve and it ran dry. Even switching back to a full tank, it needed fuel directly in throttle or fill the tubes at the pump. I took a water bottle and put a small hole in it and kept squirting till the fuel lines refilled with gas.

I'm assuming when you said it ran fine when it did start, that it REALLY does...consistent idle, no bogs, runs out well. That being said, I would not immediately go to the carb. If it were in my shop, I'd check cranking spark energy, check cranking pressure, adjust valves, and recheck cranking pressure after adjusting valves. Dr. Dave

Hey guys thanks for all the help. A pile of evenings later and it up and running. Was a tiny wire broke off at a junction

Great topic and information, for everyone who rides. I was new to ATV riding last year. The dealer I purchased from included a free entry for The ATV Safety institute safety course. I'm a senior so, crashes are something I cannot afford, I jumped on that free course. New riders do need to take precautions, there are too many ways to end up with a serious injury or death if you are not careful on ATV's.

My recommendation is start with a smaller quad and get comfortable with it before getting something bigger like a 700cc