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I thought the reeds have not been checked? This should be #1.
I'm Also not seeing that the tps has been set with a high quality voltage meter. This should be #2.
With these eliminated then you can move into everything else that has been suggested.
First of all I want to say that this is not your fault that it isn't running right and you have had to take it back so many times. It shouldn't be up to you to offer solutions to the authorized Polaris dealer on how to fix it either. Take it to another dealer as suggested by Polaris and others on here.
When you picked it up the last time did they say it was good to go or did you just grab it? It kind of sounds like he wasn't done working on it to me. Has the ECU been changed out yet?
If they fix it at the other dealer trade it and join your buddies on Doo. Sounds like you have a great sledding area if you're still able to ride at this time of year.
Like I said above find a new dealer. How could any competent mechanic forget the exhaust sensor, that tells me they did not run it. Any mechanic with any brains at all would here a massive exhaust leak. I guess you can't help those who can't help themselves. Peace out
these are the things to have your new dealer do first. compression and a leak down test. you can have good compression but have a ring sealing issue? this cause's poor idling and erratic peak rpm's.
tps has to be set right. meaning the base voltage with the throttle cable unhooked, idle screw backed out, and the throttle plates fully closed, has to be .700 vdc. if not the tps sensor has to be moved to obtain this. then the idle screw turned in to reach your idle spec voltage for your sled. then a slow sweep check both throttle wo and back to idle position. a couple of times.
throttle lever free play of .015-.030 or the thickness of a credit card has to be set.
throttle safety switch should be replaced or tested.
pull the recoil. the air gap at the crank position sensor and the trigger coil has to be checked. .020 air gap. this being off the sled will die going into reverse and cause erratic idle.
wiring above the throttle body's , and al connectors there and at the ecu etc. should be inspected closely if non of the above changes any thing?
stator out put needs to be checked. the d-wrench won't tell you the stator is bad. key codes are low voltage to the fuel injectors, low battery voltage, etc.
if this all checks out then replace the injectors. all of this if the reeds are for sure new.
a bad ex. temp sensor does not cause erratic idling. a bad water temp sensor does not cause erratic idling, a bad t-map sensor could? but not usually.
good luck. I love problems like this. never been beat yet. there is something wrong? it takes a relentless checking of everthing systematically.
First think I'd do is send the dealer that sold it and worked on it( I assume this is English Brothers?) a letter stating that you intend to sue them in small claims court.
If they don't offer you something worthwhile from that then file the max amount in Small Claims, guessing that's $5k.
Doesn't cost much to get their attention, typically this will move things ahead at a faster pace.