Category Archives: ATV Repair and Maintenance

2003 330 motor swap

I have a 4×4 330 and I found a really cheap 700 4×4 with a bad motor would the 330 bolt to the transmission? I know I would have to do some wiring and engine mounts I just don’t know if they use the same transmission and what other stuff would I run into?

Stripped wheel stud

My first problem on my 2013 550 is one that I caused. I must have over torqued one of the lug nuts and stripped the spline on the stud or the hub. I have since bought a torque wrench. I’m hoping that it is only the stud and not the hub too. Any suggestions on how to get the nut off?

Sportsman 500 running hot

I have a 2000 sportsman 500 4×4 that has been an awesome machine. Mainly use it to hunt. Two weeks ago it ran hot for the first time. I pulled everything apart and discovered the wires on the thermal sensor unit on the radiator burned up. After calling Polaris and choking on the 95.00 price I found an aftermarket replacement for 28.00 shipped from Caltric. Several folks on the net have done the same. Anyways I put it in today and still running hot. I can run the fan straight from the battery or if I unplug the sensor and jump the wires on the atv side the fan comes on. Caltric says I need to consult a repair shop. I think the fan normally comes on just by turning the key on then shuts off once you start moving until the engine gets hot. It does not come on now when I turn the key.Is that correct ? Should I have just bought the part from Polaris ? Any ideas ? frustrating. Thanks, Pete

2005 Sportsman 700 carb issue.

I have posted this in a few places with no response so here it is again…..
I took the carb out rebuilt it, removed the plug for the pilot screw and cleaned passage. I turned out the pilot screw from the factory set 3/4 turns to 1.5 turns on the bench to have a starting point. The quad starts real easy when choked and fast idles great with choke out. I can rev the quad with the throttle and good response, but as I slowly push in the choke once the quad is warmed up it responds well and the rpm comes down but at about 2000 it will run away on me and rev very high. As I continue to push in the choke it is all well until about 1300 rpm when the quad just quits. Will not start with choke at this position either but will start really easy if choked again or applied throttle. HELP!:stupido:

95 xplorer crankcase rebuild

1995 polaris xplorer 400 4×4. The piston broke and knocked a hole in the crankcase. I have another crankcase but I need to tear my old one apart so I can get the crank out. I’ve looked on the internet but haven’t had much luck finding anything on how to take it apart. Does anyone know of some tricks or things to watch for? Or possibly some links on how to do this. Any help would be great. Thanks

2005 Polaris sportsman 800 efi problem help!!

hi I’m Caylee and I own a 2005 Polaris sportsman 800 efi. awhile back I had noticed that the fuel gauge had gone bad because it would read full when it was not , it would be completely empty and still read fuel or half tank. a couple months after that I went riding and about 45 mins into my ride my fourwheeler had completely shutting down, acting as if it was out of gas. I pulled over and I noticed that the piece that connects from my airbox to my engine had only one bolt in it and was slightly hanging off . thinking that this was the problem I fixed the problem as soon as possible and thought that this was the solution to my problem. after that it I drove it again to begin back on my ride and about 30 mins it would do the same thing, start puttering. we let it sit for a little while and it would start up just fine . it kept doing that every so often. so I left it at my boyfriends house overnight and he cleaned out the radiator and it was very nasty so our other idea was that the clogged radiator was the possibility of the problem and that it wasn’t getting enough air which caused it to shut off. after that I had no problems with it and it drove fine. just today after letting it sit for about 2 weeks I put fresh new gas in it and pulled it around back to wash it off. I sprayed it down let it dry and started it back up and drove toward my garage and instead of it puttering and shutting off it just completely stopped. I turned the key and the efi is making a much more deeper sound than usual also this time it will not even catch fire even after letting it sit for over about an hour. idk what to do and I’m not sure if it’s the fuel pump or possibly the fuel injector. . but if anyone has had this problem before it would be so much help. the nearest Polaris store is about 1 hour away from me and I’d rather know the parts I need to get rather than buy the wrong ones ! thanks so much. I am opt to send videos of the start up sound too.