Category Archives: ATV Repair and Maintenance

Whats your opinion on the cause?

Recently purchased a 2009 Polaris sportsman 90 4 stroke atv. Last week it was at Polaris dealer, it had a new carb, piston and rings installed. After 2 minutes of riding the timing chain cover fell off and I discovered that only 1 of the 3 timing gear bolts remained in the cam. 1 snapped off and 1 came completely out and is I’m assuming in the bottom of the motor. Is there anything that would cause this besides it not being torqued to specs or assembled correctly? Thanks

Whats your opinion on the cause?

Recently purchased a 2009 Polaris sportsman 90 4 stroke atv. Last week it was at Polaris dealer, it had a new carb, piston and rings installed. After 2 minutes of riding the timing chain cover fell off and I discovered that only 1 of the 3 timing gear bolts remained in the cam. 1 snapped off and 1 came completely out and is I’m assuming in the bottom of the motor. Is there anything that would cause this besides it not being torqued to specs or assembled correctly? Thanks

Secondary clutch help

Guys,

I need some help. I searched the threads but didn’t find a clear answer. I have a 88 Trail Boss 4X4 and am trying to remove the secondary (driven) clutch. I removed the bolt but it won’t move. A bit of pressure applied via a pry bar against the inner sheave and frame didn’t help. I looked to see if the clutch was threaded to allow a screw to be used as a press but it has a smooth bore. Sooo, how would one get this thing off if it is stuck on the shaft? I though about a bit of heat but I don’t want to damage or warp the clutch.

Need Petcock Help

Have a 1987 Cyclone with a very leaky Petcock. I find no Cyclone forms here, I post here hoping someone could tell me what other years of petcocks might work in this ones place? or even what rebuild kits are out there. and plz make a sticky for Cyclones.:hmmm:

2009 Sportsman 500 No head or tail lights

Hello everyone! This is my first post here, but I have been lurking for the past few months when I bought my 2009 Polaris Sportsman 500 HO atv last fall. It has been a good atv after I spent some time giving it some love and TLC.

Before winter, I added the 3-headlight mod and the reverse override mod, using fully weatherproof sealed Hella relays. Everything worked perfect all winter for plowing snow and going ice fishing. ATV sat for a month this spring and I rode it a few weeks ago, and noticed I wasn’t getting the "R" for reverse to show up on the display. I have a toggle switch in line to disable the override so it is back to stock as well, but still no "R". I pull the headlight cover off to access my relays and wiring and everything looks good. I pulled all of my power from the red/yellow wire that would feed the reverse lights if I actually had them.

What I found was that I had no power on the red/yellow wire. I used the atv a few times since then, and once, everything started working correctly again, and the red/yellow wire had power. The next day, same thing, no power on red/yellow wire.

Can anyone point me in the right direction as to what is causing this issue??? It seems like the red/yellow wire is the power source for everything that isn’t working. Can someone point me in the right direction please??

Thanks in advance everyone!!!

Kevin

New member looking for some direction!!!

Guys,

I have a 2011 Ranger 500 Midsize that I’m having a little trouble with. When I put it in high gear it seems to stay in low gear until I let off the gas or drop the Rpm’s then it tends to shift in to high gear. It will do the same in low as well as reverse. I’ve tried adjusting the shift linkage but nothing changes? I’m wondering if any of you have dealt with this problem? Is there some sensor that could cause this to happen? Any feed back would be greatly appreciated!

Regards,

850 tipped on side, Oil in Airbox

Hey everyone,

I tipped a 2012 850 on its side this past week. (I was up in Canada and had a canoe on top.) Oil started dripping out of the airbox as I quickly tried to get it back up.

My question is, do I have anything to worry about after cleaning the oil up and getting a new air filter?
Everything seems to run well. I topped off the oil.

I thought the PCV valve issue was mostly fixed with the 2012s. Would the oil be coming up from the PCV system? I don’t want to take the PCV apart and risk having an issue with something that isn’t broke.

I know there are all sorts of threads about oil in the airbox relating to the PCV. But I did not see anything about having oil after tipping the atv over.

Thanks for your help!