I did the carb kit including needle & seat , new fuel pump and turn off the petcock and run the bowl dry after every ride.

Where the hell is this fuel in the oil coming from ??? :banghead::banghead::banghead:

I have a 94 Polaris 300. When I pulled the rope gas came out the pull rope hole so I took it apart and drained it. My buddy told me I need a crank seal and a new flywheel. Would I be able to use a flywheel from a 400.

HMF Exhausts have long been the ATV utility exhaust on the market. Their Swamp and Titan exhaust systems have always increased the horse power on the Sportsman while adding an incredible sound that completely changes the ride.

HMF manufacturers several different exhaust systems for several of the Polaris Sportsman models. Take a look at the list of models of muffler systems available for the Polaris Sportsmans.

Polaris Sportsman 1000 Exhaust: See More

Polaris Sportsman 400/500 Exhaust: See More

Polaris Sportsman 550/850 X2 Exhaust: See More

Polaris Sportsman 550 XP Exhaust: See More

Polaris Sportsman 850 XP Exhaust: See More

Polaris Sportsman 570 Exhaust: See More

Polaris Sportsman 600/700/800 Exhaust: See More

I have a 2002 Sportsman 400, which has been a great machine and I have never had any trouble with it. The battery went out on me last summer, and because it is in storage all winter I decided not to replace it until this year… well then I ended up buying a house so I needed it to plow, here is where the problem started.

I was out plowing with the quad and without the battery you had to rev the engine to get the winch to work, not sure if this is normal or not, but I assumed the machine pulled the extra juice from the battery if need be so went with it. I got about 5 passes in and coolant started leaking everywhere under pressure. No hot light was on (unsure if this model has one?). Anyway I let it cool and put it away and never looked at it until this spring because of the time I have had.

One key thing is that I don’t remember hearing the fan kick on before this happened, but can’t be certain. My main question would be if I was running lights and winch, if having a completely shot battery would prevent the fan from running?

Flash forward to yesterday. I took the front rack on, filled it back up with coolant and let it idle in the yard for at least 10 minutes. I felt the thermostat open and the upper hose got hot, then the radiator got hot etc. Still no fan, but no hot light either. I have never had the hot light come on on this machine, but I assume it has one? I didn’t want to harm anything so shut it down.

I tried to test the fan by hooking a battery maintainer lead to the fan direct and hooking that to a 12v car battery with key on (no battery in bike) and it did nothing. Is this proper test procedure or do I still need to jump the sensor? I tested right at the 6" wire lead that came off the fan.

I am getting a new battery tonight and charging and testing again, but the local shop swears up and down that is not the issue, and also swears it is never as easy as a radiator cap, so I think they just want my money.

Side note what is the best way to burp the air out of the lines on this machine? The filler hose and lower hose all come together at once which makes it kinda hard… I still do not have coolant in the overflow yet, but the radiator is showing full.

Thanks for the help.

HCED NO:51 it is a hot cam

Hey everybody. i was hoping to pick your brains, as i have already tried all my area dealers. i have been having an issue with my 08 650 outty. the coolant keeps puking out of the overflow. i was told a bad head gasket would cause this and to do a pressure test which i had done and showed it to be fine. so i replaced the t-stat, thinking it might be the next logical choice…to no avail. whenever i first start riding, just before the fan kicks on for the first time, it pukes out whatever is in the overflow bottle. it did it once more just before the fan kicked on a second time, then for the rest of the ride was fine. checked the level in the rad when i got home and it was down about an inch. i left it alone. thought maybe i had just overfilled it….but then it did it the next ride. it just does it at the beginning of the ride then everything is normal. any ideas? could it be as stupid as a bad cap? i should probably tell you i have the rad mounted on the front rack(BRP kit) so i can see how much is flowing back and forth between the rad and overflow. when i first start riding and it starts warming up, its almost a freeflow into the resi, then it squirts out, fan kicks on and it stops. then it goes back and forth like normal. i’m supposed to go on a 3 day camping trip soon and need to get this resolved. any input would be helpful. thanks

Just bought a 2000 Scrambler 400 4×4. It wasn’t exactly what I was looking for but I know it’s history and my buddy gave me a crazy deal. Needs 4×4 work, but when it’s fixed it should be good to go. I’ve been thinking that whatever quad I got needed to plow my driveway (3 cars wide, maybe 40-50′ long). I know that you aren’t really supposed to tow or drive super slow with these things because of belt wear. I don’t think I’d get stuck too often (4×4 plus I can get chains if needed), but will I do any more damage than probably frying a belt every few years? I have replaced these belts before and they aren’t very expensive and are easy enough to do. Before I go buying a plow kit I want to make sure I’m not going to be harming anything else.

Thanks!

Decided I wanted to try my hand at powder coating so I picked up one from Harbor Freight and a pound of satin black from Eastwood. The electric oven I used was free from Craigslist. So far they have been holding up quite well. Definitely a bit of a learning curve but worth the time and effort.

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Decided I wanted to try my hand at powder coating so I picked up one from Harbor Freight and a pound of satin black from Eastwood. The electric oven I used was free from Craigslist. So far they have been holding up quite well. Definitely a bit of a learning curve but worth the time and effort.

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Hey guys, put a Supertrapp slip on exhaust on a 2011 Sportsman 500 …. It was from a RZR but made it work …. Bike sounds and runs great just found out when on the throttle full tilt and you let off it backfires a lot. Changed out the plug, same issue. I’m going to assume it’s running lean? I was told no jetting required after swapping them out. If jetting is required does anyone have some specific info on what is required vs trial and error?

:ugh2: