I have recently brought myself my first quad bike. it brought it with a staring problem where when you turn the key to crank something trips and the ignition lights all go out and nothing happens. I could get the engine started my bypassing the starter switch and switching the starter solenoid directly. (have now fix this problem with a start button and relay ect)

I started by cleaning connections and earths and then i had no ignition lights at all. so started digging and found that there is a 6 volt drop thought the ECM (of witch part number has been recalled) so i run a feed from the battery to the output side of the ECM and all the ignition lights come back to lift and the engine will start and run, But the fronts hub will not engage does the ECM control the AWD.

I have a 1993 Polaris Trail Boss 250 that I have been rebuilding from frame up. I’m pretty well complete, but have one nagging issue. Electric Start. Its a long story, so I will start at the front.

I bought the bike, and the owner told me it needed a battery and a solenoid. He was right No DOUBT. He had been running the atv without a battery at all for quite some time, which I know can damage things, but I still took the risk. The solenoid was only half there, looked as they broke one of the studs off and said screw it. Since there was no battery, there was no positive cable. On my rebuild, I replaced all of it. Fresh brand new battery, fully charged, brand new positive cable, brand new solenoid, and all wire connectors. Put it all back together, and rolled it outside.

Turn the key on for the first time since my rebuild so I’m checking all the lighting and such to see that it works. Headlights, dashlights, taillights all work fine. the 4X4 light on the demand button on right side of handlebars works. So Im getting power everywhere. I hit the start button and hear a big CLICK on the solenoid. Thats all it does everytime the start button is pushed. Just Click. Starter does nothing.

So i get out a tester and start testing wiring to make sure im carrying power everywhere, And I am. Im getting power from one end of the wires and cables (at battery and solenoid) all the way to the other end. I tested all wires. Its even showing I am getting power to the starter when the start button is pushed.

Next I pull the starter. Well when I took the pull start case off to get to the other two bolts for the starter, a bigg rush of gas and oil come out. Crank seals bad. So I replace those, clean everything all up with contact cleaner, and then I start to look at the starter. Its full of gas and oil. So I first take some jumper cables and hook to the truck battery and try to roll the starter that way. Does Not Work. Tore the starter apart and cleaned it with contact cleaner, let it dry and put it back together. Tried the truck battery trick again and BAM it works. Starter is rolling. So im thinking Im in good shape.

Put it all back together, and still…. CLICK. At this point I Sliced open the little rubber pouch just up from the solenoid and checked the fuse block and its ok.

IM STUMPED. I HAVE POWER EVERYWHERE FOR LIGHTS, THE IGNITION SYSTEM AND ALL HANDLEBAR CONTROL BUTTONS WORK. YOU CAN CRANK START IT AND RUN THE BIKE ALL DAY LONG. IS IT POSSIBLE I HAVE A BAD SOLENOID, OR SHOULD I REPLACE THE STARTER ANYWAYS, OR IS THERE SOMETHING ELSE I AM MISSING? ANY HELP IS GREATLY APPRECIATED.

I have a 1999 Scrambler 500HO 4×4. It starts right up everytime and runs great most of the time. Occasionally while riding it will start bogging and eventually die. I can let it sit for a few minutes and it will start back up and run maybe for the rest of the day or maybe only a few minutes. If I ride for 3 or 4 hours it may do it 2 or 3 times. It acts like it stops getting fuel. I have replaced the fuel filter. Just wondering if anyone else has had similar issues and if so, what they did to fix it?

I was changing a inner axle boot on my 2013 sportsman 500 and ran into a problem. When I yanked on the axle to take it out, it didn’t come out of the transmission but it didn’t feel right. So I cut the boot off and the ball bearings fell on the floor. So my question is, do I need a new axle and any ideas why this happened? All I had was a small hole in the boot. If I need a new axle are SIXITY axles any good?:motz:

I need some sort of direction from someone who know something.
I sunk my quad in a river (they don’t like that) and i just got it running.
I don’t have awd, but there is power to both hubs. The tires try to turn (on jacks) but can be stopped by hand. The armature plates hold strongly when awd is engaged. My speedo lights up, but the needle wont move. I have tried as follows:
New hub oil, both sides. (Correct fluid and right amount)
Checked armature plates and tabs, roll cages / hillard clutches, bearings, ect. all good
New stator, new pick up coil, new recoil, cover ect.
ALL fluids have been replaced with Polaris reccomended fluid.
New hall effect sensor.
Speedo is dry and clear of moisture.
I have checked power and ground to both hubs, both are good.
Tried grounding it seperately thru the small brown wires.
Somebody please give me something to go on.

Not sure if its of any help, but off the big group of brown wires going to the coil, there is one short (2-3 inch) brown wire coming off the coil with a female connector on it, with nothing hooked up. Any ideas where it goes???

Whats the deal…..I searched for hours and cant find a specific kit for 2002 magnum 500…….every other model and year…..is it the same kit as the Sportsman?
Please help….gotta get this thing runnin’ again

Thanks

I’ve been working on getting my 2004 atp 500 running right. I’m almost there but still have a problem with the thing running lean.

It starts easily (when choked) but misses and backfires when revved up. Hard to get it to idle when warmed up with no choke.

I’ve gone over it several times and have not found an air leak.

I have replaced the carb with a NEW Polaris OEM Mukini BST. I assume that it was properly adjusted at the factory. Bad assumption?

I also replaced a scored exhaust rocker arm. Checked the cam and compression release. Both are ok.

However, I may not have it timed correctly. Had trouble finding tdc by looking in timing inspection hole.

So is it a carb issue or timing?

All ideas are appreciated.

I’ve been working on getting my 2004 atp 500 running right. I’m almost there but still have a problem with the thing running lean.

It starts easily (when choked) but misses and backfires when revved up. Hard to get it to idle when warmed up with no choke.

I’ve gone over it several times and have not found an air leak.

I have replaced the carb with a NEW Polaris OEM Mukini BST. I assume that it was properly adjusted at the factory. Bad assumption?

I also replaced a scored exhaust rocker arm. Checked the cam and compression release. Both are ok.

However, I may not have it timed correctly. Had trouble finding tdc by looking in timing inspection hole.

So is it a carb issue or timing?

All ideas are appreciated.

Are the NGK Platinum’s any better than the Copper plugs?

Gonna pull mine and see how it looks, may try the Platinum.

Mine is an NGK BKR6E.

Search Results Page | Canadian Tire

What’s the trick to getting the belt off, I know that you have to spend open the back pulley so that the belt goes down so you can get over the clutch , having trouble spreading open, kinda a dumb question but have only changed one belt one my old merc snowmobile back in the 70s, Thanks:nixweiss: