Do anyone have the 07 polaris outlaw 525 irs service manual for it. U just picked it up yesterday and have never owned a polaris before.i have looked everywhere with no look all comes up is the 2009 model. If anyone could help I would really appreciate it. Thanks and God bless

i have a 95 polaris magnum 4×2 starts and runs great until it gets hot then i lose all electrical power
i changed the ignition coil what else could it be

I have an old 350 L Polaris Trail boss. It was running great, then started to backfire and eventually died. It does not appear to be getting any spark to the plug any longer. has anyone else gotten through this? If so, what did you do to fix it?

i have a 2007 500 Sportsman x2 im working on. the front diff internals where all wasted so we bought a brand new diff. This is the unit that has the reservoir system connected by a clear hose filled with fluid. Unit has AWD, 2×4 and Turf Mode

With new diff installed the drivetrain has a binding sensation from 5 mph to stop and you hear noise like a spring loaded paw trying to fit into a gear but cant until everything stops.

should front and rear tires be different heights possibly.

Has anyone had to replace their cam chain. I believe I snapped mine on a 2012 850 sportsman. Is it a complicated job? Am I better off bringing it to the "DEALERSHIP"?

Hello all. I am new to the forum. Need some help.

Symptom: Radiator Fan will not turn on. ATV overheating after 10 minutes.

Items done. Tested fan with 12 volts. runs beautiful. New radiator installed. All new lines. New rad cap. New thermostat. New fan temp sensor (located at bottom of radiator). New water pump aluminum propeller. New water pump seal. I have good coolant flow in the radiator neck. New overheat sensor installed. New coolant. New oil change with new oil filter. New spark plug and spark plug wire. New cdi module. Man I am frustrated. Bike runs well just out of ideas. Need help! Bike will start to run hot after about 10 min. Light come on on console. Top and bottom rad hoses are hot. Radiator is hot. I can jump out the temp sensor in radiator and fan runs.

Any ideas? Please help!

Hello all. I am new to the forum. Need some help.

Symptom: Radiator Fan will not turn on. ATV overheating after 10 minutes.

Items done. Tested fan with 12 volts. runs beautiful. New radiator installed. All new lines. New rad cap. New thermostat. New fan temp sensor (located at bottom of radiator). New water pump aluminum propeller. New water pump seal. I have good coolant flow in the radiator neck. New overheat sensor installed. New coolant. New oil change with new oil filter. New spark plug and spark plug wire. New cdi module. Man I am frustrated. Bike runs well just out of ideas. Need help! Bike will start to run hot after about 10 min. Light come on on console. Top and bottom rad hoses are hot. Radiator is hot. I can jump out the temp sensor in radiator and fan runs.

Any ideas? Please help!

Hi guys, I’m new to the forums, but have been browsing the threads for about a month or so. There’s a lot of good info here!

This winter I’m going to be replacing the cylinder in my 92 350L Trail Boss. It’s a family wheeler at our cabin and long story short, it overheated due to lack of coolant/oil (I haven’t had a chance to really take a look as to why). Anyways, the engine has already been bored twice and the last time it was re-bored,we were told that it would not be able to be re-bored again. Thus, I’m going to buy a used cylinder and swap them out.

This is my first rebuild and my question is can I reuse the head off the old cylinder or do I need to buy new? I realize that if I use the old one, I’ll probably need to fix the warp but if the head has already been machined twice, can it safely be machined a third time or will that risk the piston hitting the head or something like that?

If I need to buy a new head, do I need to do anything to it (ex: have it machined to fit the used cylinder bore size) before installing?

Thanks for the help guys, any information you can provide is much appreciated!

Hi guys, I’m new to the forums, but have been browsing the threads for about a month or so. There’s a lot of good info here!

This winter I’m going to be replacing the cylinder in my 92 350L Trail Boss. It’s a family wheeler at our cabin and long story short, it overheated due to lack of coolant/oil (I haven’t had a chance to really take a look as to why). Anyways, the engine has already been bored twice and the last time it was re-bored,we were told that it would not be able to be re-bored again. Thus, I’m going to buy a used cylinder and swap them out.

This is my first rebuild and my question is can I reuse the head off the old cylinder or do I need to buy new? I realize that if I use the old one, I’ll probably need to fix the warp but if the head has already been machined twice, can it safely be machined a third time or will that risk the piston hitting the head or something like that?

If I need to buy a new head, do I need to do anything to it (ex: have it machined to fit the used cylinder bore size) before installing?

Thanks for the help guys, any information you can provide is much appreciated!

So long story short, I’ve done a partial rebuild on my sportsman. Water pump seal, impeller, oil seal, crank seal, head gasket, valve cover replacement, carb rebuild, new starter and bendix. Now, here’s where the problem begins. After getting everything listed above, I went to start the beast to hear her roar with all her new parts, but no luck (should have known it wouldn’t be that easy). The starter made a terrible noise. So, I pulled the cover off, and the bendix is loose. After a week, and many thrown tools, I think I have finally found the culprit, this circled in the picture, is missing…. I’ve looked up a few parts diagrams, and I’m not having much luck finding one to replace it with. Anyone have any words of advice ?

Thanks!

Adam

Attached Thumbnails