Category Archives: ATV Repair and Maintenance

Shifting problems

I know there are threads up here about this and I have read all I can find. I spaced mine like one of the links and that helped alot. What I want to know is whether or not the Primary clutch(the one on the bottom on mine, 2014 Sportsman 850 XP) should retract all the way when I go back to idle. On mine,when I rev it up the primary,of course, goes in and comes back at idle but only comes all the way back out if you cut it off. It comes out almost all the way out. Just stays about 1/8 of an inch in. As soon as I cut it off it comes all the way out. When I spaced the secondary(on top) it started shifting alot easier but it would some times before until I rode it hard and then it would become impossible to shift until I cut it off. I rode it a little and it didn’t get hard to shift but I am worried that it isn’t retracting all the way back out. The belt seems to stop at idle but I don’t know if it will after a hard ride. Advice??

2005 sportsman 800 no start

Just about ready to give up on the old girl, I’ve cleaned everything I could think of and added dielectric grease to the connections the engine will turn over but not fire I’ve checked spark by grounding to the head and frame there seems to be lots of spark but when I dump some gas down the cylinders and put plugs back in nothing the plugs are wet so any ideas on this would be great would like to take it on the trail Sunday as the 850 has tracks and not so trail capable right now thanks in advance.

Top end rebuild – 2011 Sportsman 500 HO

Hi. I finally was able to buy all the parts i needed for a top end rebuild on this quad. This is the first time I’ve ever done this type of repair.

Is there anything in particular I should be aware of? Tips? Tricks? Is there a Special tool to get the rings in the piston?

I’ve read many different break in processes. I just dont want to mess up the quad. I have a new piston, rings, cylinder, gaskets etc. All OEM standard bore.

Thanks in advance!

Fuel pressure low? 2011 800

Hey guys
Just want to ask a question about this 2011 Sportsman 800 EFI that I am trying to figure out. Starts only with a lot of cranking cold. Or a squirt of gas in the intake it fires right up. No codes. So I am checking fuel pressure and the manual says 39 plus or minus 3. Doing this turning the key on and off several times it will only pump up to 29 pounds. Now if I run it the pressure will come up to 39. New battery,runs fine when it gets warmed up, not real smooth idling until it is warming up, but runs and has good power when it’s warmed up in a few minutes. What do you think? Is this normal for the pressure to be this way? And/or what else could make it to be so hard starting?
PS. New plugs good spark, fuel pressure holds for several hours after its shut off checked the resistance at the temp sensor and that seems right 3.1K ohms at about 50 degrees
Thanks

AWD Issue

Hopefully someone here can offer me some suggestions!

2012 Sportsman 500 HO

Issue: AWD is locked in High and Low range. Disconnects for reverse but will not engage again when pressing the override button. Once I go back into the forward gears the AWD locks again.

Also the check engine light with the "hot" warning flashes but stops when I move the machine. This warning often comes on during a cold start which does not make sense as the engine has not had time to over heat.

All these issues seems to have come to light after I removed a charged the dead battery.

Steps I have taken:

– Completed two AWD fluid changes in hopes that the oil may have been bad. The old oil was pretty dark. This is the first time I have changed it personally but the dealer has changed it several times in the past.

– Checked the battery and confirmed 12 Volts.

– Checked the rad fluid and ensured the radiator was clear of debris mud ect.

I have spoken to the service department which is out of town from where I am and they don’t believe it is the roller cage as the AWD is disengaging for reverse.

I am wondering if this is something electrical? Especially with the odd check engine light coming on and turning off.

Any suggestions?

Thanks in advance.

loose axle

this is pretty much any atv with a cv axle but this one is hawkeye if i grab the cv axle and wiggle it loosly in the front diff is it mostly the splines on the axle worn out or the piece in the diff that the axle slides in. i have noticed this a lot on atvs

03 trail boss 330

So my daughters bike started running rough, loss of power and backfires out exhaust when giving gas. I cleaned carb, replaced spark plug and repaired vacuum leak at carb adapter (manifold) and nothing has changed. I am thinking possible coil. Any advise?