Just wondering if anybody knows why it would crap out as soon as it his 25km/h. Engine light is on and the code says the throttle is stuck. Which it is not. It idles and revs perfect in neutral and before it hits 25. Also when I put it in gear it takes more then normal throttle to get it to move and when it does it jumps which makes it very difficult to load on a truck. It won’t feather lightly. Throttle has been adjusted. Anybody have any answers?

i’m hoping someone can help me out… My 4×4 doesn’t work (02 sportsman 400) but there is full power to both hubs. Armature plates and Hilliard clutches are brand new, filled hubs correctly. They magnatize as they should and have correct hub fluid. On jacks I can stop both tires with my hand.

New: Hall effect sensor, Hilliard clutches, armature plates, right fluid/correct amount, bypassed speedo, grounded hub wiring ect.

Another question. Where the splines / rollers on the Hilliard clutch are.. Should there be some notches on the inside of the hub for these rollers to set into when awd engages??

The speedo lights up, shows hours and Kim’s ect but the needle won’t move. (Speedo is bypasses anyways)

Because with the hub (cover?) itself off, I can see that the rollers move up when the hex nut spins on the axle… I’ve done the grounding re wiring, grounded the speedo out.. Awd light works, gear selector indicator works, power to the armature plates… Fully/properly magnatized ect. Someone please help 🙁

i’m hoping someone can help me out… My 4×4 doesn’t work (02 sportsman 400) but there is full power to both hubs. Armature plates and Hilliard clutches are brand new, filled hubs correctly. They magnatize as they should and have correct hub fluid. On jacks I can stop both tires with my hand.

New: Hall effect sensor, Hilliard clutches, armature plates, right fluid/correct amount, bypassed speedo, grounded hub wiring ect.

Another question. Where the splines / rollers on the Hilliard clutch are.. Should there be some notches on the inside of the hub for these rollers to set into when awd engages??

The speedo lights up, shows hours and Kim’s ect but the needle won’t move. (Speedo is bypasses anyways)

Because with the hub (cover?) itself off, I can see that the rollers move up when the hex nut spins on the axle… I’ve done the grounding re wiring, grounded the speedo out.. Awd light works, gear selector indicator works, power to the armature plates… Fully/properly magnatized ect. Someone please help 🙁

New to this forum… been a lurker for years… learned alot of helpful things here. Have a polaris 05 700 efi sportsman that I bought brand new. Occasionally the radiator fins would get plugged and the engine hot light would come on, a quick hose flush and I was good to go. Recently though a hose flush apparently was not enough and before the engine hot light would appear antifreeze would blow out of the overflow and then the hot engine light would appear. I decided to add the wild boar rad relocation kit. Once I had the radiator out I gave it a good cleaning and flushed the interior out. I succesfully added the relocation kit with no issues, I moved the filler neck up to the top of the radiator as well. When adding my premix antifreeze I had the front wheeels elevated approximately 8"-10". After topping off antifreeze I left cap off, massaged hoses and let idle for another 10-15 minutes. I returned atv to flat ground and put radiator cap back on and let idle, there was no antifreeze in overflow tank at this point. Within 10 minutes antifreeze was blowing out the overflow followed a couple minutes later by the fan coming on which effectivly did cool the rad and all antifreeze in overflow went back into the system. Tried idleing numerous time with same results. I have tried all of the following:
a. New thermostat. Checked both old and new in boiling water and they are good.
b. When running both hoses get equally hot telling me I have circulation.
c. pulled circulation pump cover to insure impeller nut is tight.
d. Appears to have no oil in antifreeze or antifreeze in the oil.
f. Changed head gasket anyway.
g. Appears that no antifreeze is leaking at weep hole under water pump.
h. fan does come on
i. When I unplug temp sensor fan comes on immediately.
j. New radiator cap.
After all this started up and same thing…….. after 10 minutes of idleing…. antifreeze out the overflow!

Sorry for writing a novel but I am at my wits end with this. What am I missing? Any help would be greatly appreciated….. before I drive this thing to the bottom of Oneida Lake….. just for fun!

I’ve tried just about everything to get this damn piece out. Prying, yanking on er, even had it strapped to another ATV and it tore the boot in half.

Y’all have any ideas on how I should go about getting it out without destroying my t case. Attachment 25651Attachment 25652

On a Sportsman 570

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Ok have read a few post close to my issue but… Here is what mine is doing. As soon as I hook up the battery the fan runs nonstop, the switch doesn’t even need to be on. Once I turn on the key the temp light comes on and of course fan stays on to, the atv runs fine but obviously will kill battery in no time since the fan doesn’t stop. I did test the thermistor switch an it has 111 ohms at room temp, as I heat it the numbers drop. I tore it down to clean the carb an before putting the plastics back on I sprayed everything down with purple power an washed it, started it right afterwards to make sure I didn’t water soak any electrical parts and it was fine then, just noticed this issue the next day after it sat over night. Any help?

Hello friends. New to the thread because I am new to Polaris. I just picked up an 04 700 (Non EFI) with some issues I am trying to figure out.

It runs great WOT but won’t idle unless choked. Even then it sometimes quits. When i keep the RPMs around 3k it runs, otherwise it dies.

1. Carb was cleaned recently, but parts NOT replaced (guy said not needed)
2. New plugs
3. New fuel
4. I believe the previous owner upgraded the ignition system.

Idle needle and seat maybe? Any other common causes?

It seems like a nice machine. I look forward to seeing it run right.

Hello, I am new to the forum. Lots of experts on this forum! I have had my 2003 Predator 500 for about 5 years w/o any problems besides the regular maintenance. Last year I had a cheap Batteries Plus brand battery that left me stranded twice on the trail. I replaced it with a YUASA YTX9-BS battery from the Polaris dealer, but after I connected the positive and then tried to connect the negative, it started sparking and melting the ground terminal. I thought I may have overcharged it, so I bought another battery, but had the same results. I don’t think it is anything major because it was working fine with the cheap battery, besides not starting after a long ride. Not sure if it may be a starter/solenoid issue? Thanks for any advice you can give me.

Hey guys,
I’m new to the forum & back in early march on a ride I had to replace my belt (luckily I had an old one as a spare). Anyways, with the spare belt I noticed then the machine would creep in gear, bit I figured iy was the old worn belt I had as a spare.I bought a brand new belt for it & it seemed to be ok for the test ride I dis after replacement of about 5 miles. Well, last wednesday through sunday I went on a camping trip & this thing will now even start squealimg if your holding the brake with it in gear idling. In high it creeps at probably 3-5mph & is impossible to shift when it is running. I also hear wierd little rattling sounds coming from it now as well. I was gonna order a clutch kit for it as I’m pretty sure that is the problem but figured I’d ask people with more clutch knowledge than me before I spend money on it… I am mechanically inclined, but not very knowledgable on cvt transmissions yet.

Thanks in advance!

Hey guys, need a hand on my 09 sportsman 400 ho. It magically developed this issue- go to the garage. Hit the key, it will fire up perfectly. But after 15 or so minutes it will die. BUT if you pull the choke and work the throttle it will try to fire. Let it sit over night and the exact same thing happens.

I’ve pulled the fuel lines, seems like there was fuel at the carb. But let’s pretend I didn’t do that and start fresh.

Any ideas?