I’m starting to get a bit nervous about the state of my 2012 Sportsman 500 HO (1500 miles approx. 150 hrs). Last night, i went for a ride and found a mud hole (mostly water) and i didn’t know how deep it was so I eased into it and slowly worked my way across. The water only came up just over the running boards. I got hung up on the opposite side and rather than hammer on it, I just grabbed the winch and pulled myself out. Pulled over to the side and turned it off to wait for my buddy to come through. Once he crossed, i went to fire it back up to continue on, and it would not start. Turns over fine but will not fire. Got towed out and picked up and today I started digging. First, I checked for spark. Got that. Then I checked for fuel, got that too. Then i checked the resistance of the ignition coil, and the pulse coil, both check out just fine (makes sense because its got spark). At this point the battery was getting low, so i put it on the charger until completely charged. Still won’t start (still turns over fine). I should mention that a few times while trying to start it, it backfired out the exhaust.
Continuing on… I decided to check if the flywheel had sheared the key off. It doesn’t appear like that happened. Everything in there is tight. I figured since I had gone this far, might as well check the valve clearance. Here’s where I’ve found a potential issue. When attempting to set TDC it seems that either the flywheel is lined up, or the cam gear, but not both at the same time.
First picture attached: Timing mark on the flywheel is lined up with the sight hole in the recoil cover. Cam gear is in the position shown.
Second picture attached: Cam gear is lined up as shown in the manual, on centerline with the crankshaft, and the timing mark on the flywheel lines up with the top bolt on the water pump!
I rotated the engine around probably a dozen times or better and each time, this is what happened. My only assumption is that something slipped when attempting to start it and the result is this. The timing chain seems like it’s tight and it doesn’t seem like it skipped a tooth (or several) but I can’t figure this out. Please help!
I’m having to buy new batteries again. Does anybody know of a good battery for 2007 Sportsman EFi? Does anybody use the lithium ion batteries in there quads? And where is a good place to buy online.
2010 sportsman 800 Spotters coughs won’t hardly run when going through water very fast water only 6 inches deep when steam stops it runs very good can I seal this fan or do I have to replace it. Or is there some of the reason for all this appreciate any help ,thank you ripraven
2010 sportsman 800 Spotters coughs won’t hardly run when going through water very fast water only 6 inches deep when steam stops it runs very good can I seal this fan or do I have to replace it. Or is there some of the reason for all this appreciate any help ,thank you ripraven
2001 500HO
Running at about 40mph and after a few minutes engine loses power and backfires. Starts back up and won’t do it until it runs for some time at that speed. Will run at 30-35mph without a problem. Has done this twice and
I believe both times were first ride of the season. Problem didn’t happen on return leg of both trips and on subsequent trips. Has started doing this since I installed a carb kit. Any ideas where I should start looking.
I have a 2007 trail boss 330. The CDI failed. I bought a cdi off of a 2005 polaris sportsman 500. The plugs were different, the 07 was a 8 pin connector with 6 wires and the 05 has a 6 pin with 6 wires. I compared both wire schematics and got the 05 cdi to work.
The problem is, it starts and idles fine with the 05 cdi but when you go full throttle it has no power. It cant climb a hill and it tops out at 25 mph. Other then driving like its a 50 cc quad, it runs great. What is the reason the the cdi doesn’t work? I know the power curve is different but I thought it might operate better.
Hey guys, just got back from a little ride. One of my buddies pointed out to me my front right headlight was out. I figured maybe the cable had come undone, or I had blown a bulb. Both taillights were working – until I pressed the brakes. Then, the right taillight also faded and also went out, until I let go of the brake. I really don’t think I could have blown the bulbs, and the connections seem to be secure. What could be causing the lights not to work? I have a friend that might be able to help but he doesn’t know much about Polaris wheelers…not to mention I’d rather get advice from people who won’t tell me "Don’t buy a Polaris". Thanks for the help!
My wife did not realize the parking break was on and drove a few hundred yards before a puff of smoke let out and she finally realize it was on. Then drove only a few miles after that. Following week we were on a dirt road full throttle 45 mph for 10 minutes and belt shreds! Was it the parking brake from before or the full throttle on the dirt road? 2003 sportsman 500 HO. Thanks for the help. Just bought atv used so no clue if belt was new or original!!!!
It’s pretty basic, the axle cup is stuck in the trans. Tried to pull the whole axle, but nothing. Tried to pry it. Nothing. Used a 3 1/2 ft prybar on the exhaust clamp, nothing. Currently have an exhaust clamp and then attached a slide hammer. Went up to 45lbs on the hammer and the cup still won’t budge.
Any other ideas? It’s been soaking in PB blaster for a week now. What’s next, say the heck with the ring gear and plasma cut the cups out?
Hi, I am new to the forum and I know this topic has been discussed to death as I have been researching it for the last few weeks. Just hoping to get some direct help as I have reached a kind of grey area in my repairs. The last ride this bike was on was about a year ago when the battery stopped charging and since then has been put aside. Two weeks ago I decided I would try to fix it now that the time and money was available and the weather was nice seeing how winter is over :). First I tried boosting the bike and there was nothing. First off I installed a brand new battery and starter and voila the bike is running/driving perfect! Now I’m trying to diagnose the charging issue. From what I’ve read I’m thinking the two causes could be the ECM (engine control module) or the stator? Correct me if I’m wrong, hence why I am asking for help. Any way to trouble shoot these to see what my problem is? First real electrical job so just seeking a few pointers! Thanks and sorry if I posted this in the wrong section etc.
