Category Archives: ATV Repair and Maintenance

ECM Module

Hi, I have a 2008 500 Sportsman HO Carb. About 6 months ago it had complete power loss. I unplugged the ECM harness and plugged it back in and power came back on. The only issue was I would just turn the key without starting it up and the display would flash hot engine. I just ignored it and its been running great. Yesterday went deer hunting in the rain and it poured all day. I got back to camp and went out to move it and again, complete power loss. I unplugged the harness from the ECM and it came back on but loses power. The display is saying im in reverse when Im in part. Says im in 4 wheel drive when Im not and flashing hot engine. Its freaking out. What should I replace. Thanks, Neil

winch broke?

I had the toggle switch fault on me and could not hear the winch strain in the in position and I think it burned out? I replaced the switch. It was working really slow and then stopped all together it’s a off brand 3500# looks almost identical to a super winch? can it be repaired could it be the brushes that just wore down to nothing or running these in stall position wrecks them beyond? I have not taken it apart yet. But it was a decent winch so I want give it a try? Or is this just a throw away item?

winch broke?

I had the toggle switch fault on me and could not hear the winch strain in the in position and I think it burned out? I replaced the switch. It was working really slow and then stopped all together it’s a off brand 3500# looks almost identical to a super winch? can it be repaired could it be the brushes that just wore down to nothing or running these in stall position wrecks them beyond? I have not taken it apart yet. But it was a decent winch so I want give it a try? Or is this just a throw away item?

2012 Sportsman 800 starter solenoid

A couple weeks ago I started having trouble with the starter solenoid. Same issues I was having last time it went out. Decided to order one online. Replaced it
The next couple weeks the bike cranked and ran fine. Friday I was at the camp and cranked the bike and rode around probably 15 minutes. When I turned the key off it sounded like the starter was engaging and disengaging. Turned the key on and back off and it stopped. Now the bike wont crank or come on at all. The guages wont even come on. Its like Im getting now power at all.
I checked the fuses and tried another solenoid. Still nothing.

Any ideas would be appreciated.

02 trailblazer 250 out of ideas

Hi im new to the forum. I have an 02 trailblazer 250 2 stroke, it has sat for several years. I got it going again and it rode fine. I let it sit for another month due to work and now when I ride it will ride fine has plenty of power, but as soon a I hit the slightest puddle it boggs out to the point where it wont even move under its own power. I can sometimes put it in neutral and rev it up then when I put it back in gear it will go, sometimes it wont rev at all. Ill put it back on the trailer and when I go to pull it off, it runs fine again. I have cleaned the carb/jets out several times. I have been changing out the plug almost every time I ride it. The plug will be really blacky almost greasy looking and sometimes soaked in gas. I took it to my local mechanic and he said when he turned the fuel to reserve it ran without any problems. He thought the fuel system may have been clogged. I take it to the trails and the first puddle I hit, it happens again. Srry for the long text but Im just out of ideas. Could the carb need a rebuild kit? Could I be sucking water in from somewhere. Thanks in advance

My 2004 polaris sportsman 700, cracked cdi box

I have a 2004.5 polaris sportsman 700 with no spark, it has the polaris factory DC ignition system fix, but I found A big crack in the cdi box so I’m going to start with that. I found a cdi box on line for a 2004 polaris sportsman "600" and was wondering if it will work, is it the same as the one for the 700? Looks exactly the same as my cracked one in pictures except it came off of a 600? Please help me.

’02 shifter issues

Trying to get my sons sportsman 500 up and running. Shifter froze in low and would not move, my son has managed to get it back to neutral(lights on) but will not go into any gear but low. Drove the quad in all gears last week, no problem. Son says this has happened before and force worked then. Seems to be the shifter itself but i’ve been wrong before. any ideas?

Exhaust manifold bolt removal

I posted thin in new members forum, should have put here. Need to change exhaust manifold gasket on my Sportsman 600, 2004. Not much experience so I am looking for advice on bolt removal. I dont want to break trying to remove. Additionally 1 week until deer season, do I risk any damage to my engine by running with the gasket leaking? Thanks
Bill

Sportsman 600 drive (secondary) clutch

Polaris Sportsman 600 Twin started to breal down belts and finally it destroyed the bearing/pushing in the secondary clutch. There was crashed metal in the box.
I have the new pushing but wondering what is the function for that because it does not fit into the inner plate. Is it just hanging there on the axle inside the spring? There is then a big tolerance within the axle and the plate. The washer shown in the part picture is much bigger for real as can be seen in the 1st pic. In the 2nd pic the bearing/pushing is in his place as well as the washer. The part numbers do match but somehow it is not logical.. Any hint?

Attached Thumbnails

Sportsman 600 drive (secondary) clutch-1.jpg
 

Sportsman 600 drive (secondary) clutch-2.jpg
 

Sportsman 600 drive (secondary) clutch-3.jpg