I have a 97 Polaris Xplorer 500 4X4. The bike cranks and idles great but when you rev it up it starts to cut out and miss, press in the override switch and it revs normally. In either hi or low gear you must have the button pressed for it to run good and not miss but even then once you get to about half throttle it starts cutting out again. Also the AWD will only work with the override depressed.
Pull black wire comeing off rectifier it bypasses the override I just had this issue with mine because reverse switch sticks and tells wheeler it's in reverse
Sounds like it thinks it stuck in reverse
SOURCE: 97 Polaris Xplorer 500 4X4 rev problem
REPLACE THE CAMSHAFT !!!,,, HAVE A LOOK AT CAMSHAFT , EXHAUST LOBE IS PROBABLY WORE RIGHT OFF....
SOURCE: 97 polaris 500 sportsman 4x4 atv carburetor
If you have gone through the carburetor and your atv still won't rev it sounds like the exhaust lobe on the camshaft is going flat. They have an overhead camshaft in the 500 motor and the exhaust lobes seem to wear down if the oil is broken down (gas in oil) or if the wrong oil is used. Easy way to tell is to remove the 8 screws on valve cover and the spark plug. Then remove the 4 screws holding down the rocker arms. Once the rocker arms are removed you can see the camshaft, pull on the recoil rope to rotate engine until the lobes are facing upward. The two outer lobes are the intake lobes, and the center is the exhaust lobe. If the exhaust is worn, you will definitely be able to tell because it should be about the same height as the intake. Or if you don't feel comfortable doing that I would recommend a reputable repair shop. Hope this helps, and if you need more help let me know, Daniel.
SOURCE: what do I need to check
Oil level good ? Fins on head clean? Or could be electic componets braking down due to heat start with checking resistance at primary coil
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