AWD issues with the 2005 Polaris Sportsman 500. AWD is not engaging. Switch is on and the indicator light on the cluster is on. Switch is off and the indicator light goes off. Ran some electrical tests: Checked the gearcase coil resistance @ 24ohms (good); Checked the battery voltage at the hub coil wire at around 12V +/-; Continuity in all the related wire checked out. Before I take the front gearcase apart to check for internal issues, am I missing something? Anyone have any ideas or solutions?

So I picked up a 02 700 Sportsman for cheap I think. I took a risk and I am hoping I make out pretty well. It is 13 years old and still has the original tires with just over 1400 miles.

Anyhow it eat up the coolant fast and the oil is clean. I’ve had it now for a couple weeks, but thought Id check the problems out myself rather than just going from the old original owner. So from my research, im thinking it could be the head gasket or/and the head could be warped. So I am going to try the head gasket first. So it there a good process on changing it and bleeding the system out when I am finished? I am also going to change the oil also.

I did find a PDF manual online, but nothing about changing a head gasket. So to you guys who do this more than I do, I hope to hear your ideas.

The mud scrambler managed to get a lot of mud and water into the stator housing.
Waterpump seal has failed, so I’m busy getting this fixed.

Anybody been there done that?

Hey guys, new to the forum. Need some help. Daughter was driving the quad couple days ago through deep snow and was running fine. All of a sudden it started acting like the reverse speed limiter was activated and keeps bogging out under acceleration. Quad will start run and idle fine but when I accelerate it only moves forward a few feet then cuts out and then a few more feet and cuts out. Changed the plug, got new fuel in it, cleaned out the air box, checked the belt, all seems fine. It just spontaneously started doing this. Wondering if there is an electrical component that would cause this if it got wrecked going through the deep snow? Any ideas?

Does anyone know the starter bolt torque specs for an 09 850xp ? I cant even find the starter in the Midwest Manuals service manual ! Thanks

I have a 93 trailboss 350l 4×4 its liquid cooled, 2 stroke. I bought it not running, had bad compression, I’m redoing the top. I just got the motor out of the frame, and I need to check the water pump.
1 st, does this engine have a counterbalance ? And if it does, is it in oil?
I know this may be a stupid question, my service manual is vague, there is one bolt on the case near the balancer is, and it had antifreeze in it. If anyone has any info on this, please enlighten me, thanks

good day all! looking to extract a little info from the many knowledgeable people that reside on this forum. i have an old 93 sportsman 350 2 stroke i bought awhile ago, mainly to move snow in my driveway and some trail riding. anyway got a lotta snow last nite. 1st of the year. start the old girl up and drive out of the garage and , well get about 10 feet and the throttle sticks damn near wide open!! then as im freaking i find out the damn kill switch dont work!!! not a good start to the day.
anyway the question i have is what would make the throttle stick? used it several times over the summer with no problems. took cover off by thumb control. everything looks ok. freeplay seems right. could not get it to stick messing with it in the garage. i thought these throttles were nt supposed to stick?? or kill the engine if they did when you let off?! any body got an idea?? sure could use an idea or two.
thanks
kevin

One of our sled batteries finally gave up. Instead of buying a new one i was planning on using the battery from the quad (good AGM). The question is will the bike computer mainatin all the settings (service interval, hours etc) after the battery is removed and not replaced likely till spring?

Can any one tell me what will fit in my bike? I blew the front diff and have been looking for a used one. I have found a few that have the part numbers 1332828 and 1332804. My part number was 1332963. Also all the listings I have found say from year 09 to 13. Mine is a 14. When I look the part numbers up the numbers have been superseded by the 1332963 number. Did Polaris change anything or just changed the part numbers. Last thing I want to do is by one that has any more issues than the one I had. Already going to have to do away with the ADC so I can put on the billet front on the one I get. Any help would be appreciated.

The threads for the rocker arm bolt pulled out of the head, will a perma-coil fix this problem or will it pull out ?

Thanks