Category Archives: ATV Repair and Maintenance

EFI continuing issues 550xp

09 XP. Last year the EFI went out 9 miles from camp on my annual hunt trip and required a long walk out.

This year, though I thought long and hard on taking my wife’s carburated Grizzly, I again opted for the Polaris. This time (though fortunately only about 4 miles from camp) going up a hill it just died. I checked the spark and it was strong. I run one of the Platinum NGK 4 prong permagap plugs. I pulled the output line from the fuel pump and I was getting absolutely no fuel delivery. I hunted from my truck the rest of the week.

When I got home I pulled the front and pulled the 20a efi fuse. It looked perfect so I put it back in and cranked it over and it fired right up as if there never was a problem. I’m baffled and don’t ever want to take it more than 2 miles from safe harbor.

Two questions please.

1. with the fuel line off the pump, shouldn’t I have had fuel spurt out on turning over?

2. Can anyone confirm what I read " that if you disconnect the gas tank filler, you can tilt the tank enough to get the pump out without removing all the front plastics?"

I am seriously considering carrying a spare fuel pump.

New quad, broken winch?

Hey guys so I finally picked up my own Sportsman yesterday a used 850 XP LE with EPS. And everything seems to be good except the winch. It is the polaris 3500 lb series with synthetic rope.
When I hit the switch the lights dim a bit like normal and you can hear the click but the winch doesn’t turn. I tried switching it into free spool and back again but it didn’t seem to change. I haven’t had much time yet to play with it but was wondering if anyone has seen this before. It has some mud stuck in it so I’m thinking maybe that has something to do with it? Or maybe the free spool switch is broken.
Thanks guys.

Sent from my D6503 using Tapatalk

No Electrical power

I have a 93 350L I put in a new battery and starter solenoid. I now have no electrical of any type. No dash lights, shift lights or tail light. If I jumper the solenoid the starter turns over but won’t fire. The new battery tests fine. It will no longer start with the pull starter either. The previous weekend it would always start 1 to 2 pulls. Is there a main fuse somewhere I am missing? Because that is what it acts like.

Thanks,

No Electrical power

I have a 93 350L I put in a new battery and starter solenoid. I now have no electrical of any type. No dash lights, shift lights or tail light. If I jumper the solenoid the starter turns over but won’t fire. The new battery tests fine. It will no longer start with the pull starter either. The previous weekend it would always start 1 to 2 pulls. Is there a main fuse somewhere I am missing? Because that is what it acts like.

Thanks,

Am I in need of an engine rebuild?

So, here are my issues:

1) If I have the throttle in more than 1/2, after the engine has warmed up, the engine surges.

2) I am loosing coolant somewhere. It is not dripping on the ground.

3) Hard to start when hot. I have to work the throttle to get it going.

4) Once warmed up, will not stay running at idle. I have to work the throttle

5) "Hot" Light comes on. The fan wasn’t working, so I wired a switch.

All of this points to a blown engine. Would I be wrong? Can I get an engine rebuild kit at the dealer?

Not the carb – rebuilt and cleaned and adjusted.

I can do the rebuild.

Its a 1991 Trailboss 350

Steering Post Bushing

The owners manual says to grease the steering post bushing…ok no biggie right? Take off the handlebar cover and there is no grease zerk for it. So what should I use? I thought about taking a grease needle and using red grease but wanted to see what everyone else was doing.

2012 Sportsman 850 xp

Steering Post Bushing

The owners manual says to grease the steering post bushing…ok no biggie right? Take off the handlebar cover and there is no grease zerk for it. So what should I use? I thought about taking a grease needle and using red grease but wanted to see what everyone else was doing.

2012 Sportsman 850 xp

Front shaft slip yoke has a little play in transmission side

Ok…so this is the first time I messed around with a prop shaft on a quad. I have a 2012 Sportsman 850 XP EPS that I recently had a bad ujoint on the transmission side of the front prop shaft. I read how the yokes do wear out eventually so I decided to go with an entire new front prop shaft assembly. So I put the new assembly on and I noticed that there is a slight play where the slip yoke goes over the transmission side. This is the side with the grease zerk. The play is less now that the u joints are new. I am thinking this is normal as it is a slip yoke and when the pinion turns once the splines grab the yoke it shouldn’t have play in it anymore. What you are your thoughts? Couldnt really find much online about it just that some play is acceptable for a slip yoke.

Front shaft slip yoke has a little play in transmission side

Ok…so this is the first time I messed around with a prop shaft on a quad. I have a 2012 Sportsman 850 XP EPS that I recently had a bad ujoint on the transmission side of the front prop shaft. I read how the yokes do wear out eventually so I decided to go with an entire new front prop shaft assembly. So I put the new assembly on and I noticed that there is a slight play where the slip yoke goes over the transmission side. This is the side with the grease zerk. The play is less now that the u joints are new. I am thinking this is normal as it is a slip yoke and when the pinion turns once the splines grab the yoke it shouldn’t have play in it anymore. What you are your thoughts? Couldnt really find much online about it just that some play is acceptable for a slip yoke.