It wasn’t too long ago I had a spark issue and after freshening up the top end it has reared its ugly head again. I have spark with the plug grounded to the head but not while installed in the head. This is our beater quad, the one you grab for those hold my beer and watch this moments. It had major electrical issues when I got it. The 4wd didn’t work and since we already have a 4×4,, carrier and front diff, the front axles, awd switch and overide were removed entirely. The etc is gone, as in removed along with the rev limiter and the wires coming from the shifter. The only wiring left on it is the headlight switch,3 wires from the key switch, the 2 wires for the push button start to work, and the hot wire from the battery to the circuit board. The wiring is strictly bare bones for it to run, charge battery, have lights and shut off with the key and a 7 inch push fan mounted in front of the radiator that is wired to come on with the key. Stator tests fine, coil tests fine along with spark plug boot. have done continuity tests on wiring and it all checks out fine. I am at a loss. Last time this happened it was the rev limiter so I removed it and viola the problem went away. I changed the frame ground, engine ground and ran a ground wire from the coil ground tab to the ground on the circuit board. The grounds are good, triple checked them. Retested stator, coil, and key switch. All are good to go. It ran fine until it busted the skirt off the piston. Had the jug straightened out and got new top end kit for it and put it back together without changing anything about the way it was wired and now it won’t fire with plug in it. Any ideas? All I have left to do is try a different battery. I know it sounds odd to have removed all the safety switches and other stuff that didn’t work and wasn’t going to be replaced but it made it easy to track down the first spark issue. It ran wired in its current configuration for quite a while with no issues and was very reliable until the piston broke. Give me your ideas, opinions, and any and all advice is welcome.

So recently I started getting a noise coming from the flywheel side cover of my 2012 Sportsman 800, I took the cover off and noticed that my starter Bendix was sitting kinda far out and was making contact with the flywheel. I touched it and it slid a decent way in, the Bendix itself twists in and out just fine but the whole assembly slides in and out. I’m not sure if this is normal or not. Any info would help.

I have a 2014 sportsman 850xp I’m rebuilding the motor and I have to either have the crank shaft refinished or replace all together due to rod journal out of round..
My question is this has anyone ever tried to get the starter gear off the shaft?

Seems the bolts aren’t lined up.

Looking for a good set of axles for a 2008 Sportsman 700. Currently running set of 27" Mudzillas so I need something that’ll hold up for awhile, but I’m not break the bank. Any recommendations? Thank you. #BrokeCollegeStudent

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I just recently purchased a new primary clutch for my 2000 sportsman 500 with ebs. The new one is off a 2002 700 and is in great shape. I am switching my weights and springs over but will the 3211069 belt work on the new clutch? Thanks for the help!

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I have a 2007 Sportsman 500. Can not figure out why it acts like water in fuel. Has done this from day 1 New, now and then. I thought I had it figured out after I installed a small piece of 1/4" gas line on the mass fuel sender unit on the throttle body. Anyone have any ideas?

Had a guy look at his issue and he said the ‘sprag’ gear is broke. Is this thing fixable? Heard that parts are unavailable. Looking for a little insight on the issue.

It is stuck in gear at the moment; took the chain off to move it around. Haven’t torn it apart yet; just trying to figure out what I’m getting into. Thanks in advance!

Had a guy look at his issue and he said the ‘sprag’ gear is broke. Is this thing fixable? Heard that parts are unavailable. Looking for a little insight on the issue.

It is stuck in gear at the moment; took the chain off to move it around. Haven’t torn it apart yet; just trying to figure out what I’m getting into. Thanks in advance!

I got a new 850sp this year and it’s been great so far. It has been sitting for about 2 weeks in an unheated barn. I went to use it today and it seemed to start but not very smoothly. It started at first but then cut out after a few seconds. I ended up giving it a little throttle to keep it running and let it warm up a bit. Is this normal for a new machine or do I need to take this back to the dealer? It’s been below freezing this past week but nothing in the crazy below zero deg. Thanks for the help!

Re: 2000 Magnum 325 2×4

Out running the other morning and noticed the lights flickered from bright white to a dim yellowing. The battery is new and charged. My immediate suspect is a bad grounding. My question is where? Other than this issue it runs fine.

Has anyone had to trace this problem before, or have a good plan on tracking it down? I would appreciate your help on this one.

mike280
mike280@comcast.net
Triangle, VA