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.

bought a speedi sleeve to fix the seal area on my front diff but the bearing won’t go over the sleeve once installed and the sleeve is to long to put in after the bearing and would have to be cut off for any future maintenence .

those of you that have used a sleeve how did you do it

good job polaris saving 15 cents by using a single lip seal

What is the carburetor float measurement on a 2009 Polaris Sportsman 400 HO?

Thank you,

Dave

Does anyone know if there is a list of COMMON issues faced by the Sportsman 800 HO? I’m pretty sure a lot of the issues would cross to the 500’s, as well, and possibly others.

I’m not talking about a random broken CV shaft or boot, or a bad thermostat, etc. If there is another thread or sticky or anything, please include the link. I wasn’t able to find one specific to the 800 HO.

I have my 2008 Sportsman 800 torn apart for a Fuel Pump replacement and would like to know if there are any other repairs I should perform in the downtime instead of IF they occur later.

Here is what I have. If you have others, please let me know.

• Overheating – Radiator clogging.
• Overheating – 25A self resetting circuit breaker corroded
• Overheating – The impeller on the water pump warps
• Fuel Pump – Gets hot and stops working until cooled or quits all together
• Right Leg Heat – Hot air around exhaust and from radiator exits at the right ankle.
• Melting plastics – Exhaust runs VERY close to plastics causing melting
• Motor Mount breaks – I have kept an eye on mine without issue, but there are several posts about it if you do a google search.
• TBAP wiring – Wires separate from the connector and either stops functioning or starts to melt the connector
• TPS – Improper adjustment from the factory/dealership
• Breather Oil Leak – Platsic breather on top of the motor warps and begins to seap oil
• Clutch cover sealing – The clutch cover and the clutch backing plate are not sealed well, or at all, letting water into the clutch/belt system
• Ignition Coil wire harness/connector – The harness is traditionally pulled too tight causing stress on the connector at the coil and causing a no spark issue

I’ve ran into MOST of these and fixed them by searching this and other sites. So I know the fixes are available and am not looking to get into that kind of detail. Just a list of the problems this model runs into so I can either watch out or fix it ahead of time.

And yes I know it’s OLD and I could upgrade to the 850/1000 or buy a rzr, but aside from looking out for the known gotcha’s it doesn’t give me many headaches.

Thanks in advance!!!
Ryan

I need an axle for my son’s sportsman 400. I have found on e-bay these 3. Does anybody know anything good or bad about these. Which would you choose? They are all about the same price. 4x pro, sixity or American cv

edit: make that 4. Slasher axles

First post and also first 4 wheeler! Picked up a 2000 sportsman 500 yesterday. It belonged to a good friend of mine but it had been sitting for a few years. Cleaned the gas tank out, replaced any bad fuel lines, took the carb out and gave it a thorough cleaning. I got it to start a a couple times and it will idle but not good. When I give it any gas it wants to die. Its getting gas to the carb. Is there anything else I need to check? Also to note, the air filter has a big hole in it, I just haven’t had the chance to go grab a new one. Could that affect anything?

Hi – I need some new studs to hold my wheels on – the part number is 7515330.. but it doesn’t exist anymore its 5/16" 18(10) I think.. Where can I get some to fit please?

Any ideas as I lost one today and now can’t use my old quad. If there is a substitute part from another quad please let me know. That would be great.

2001 sportsman 500ho. brakes are not working, its like they work but no power brakes. I took the calipers off and pushed the pistons in and pulled the brake handle and foot brake and pushed them in and out several times. but still not working right. Master cylinder? If so were to get one and how much.

I’m miss placed or lost the old output shaft seals ,And Like a complete neeeeewb..failed to write them on my punch list.

This is out of a 2008 700 twin X2 ..800 X2 would be the same ADC gear case.

So id any one knows for certain the seal size’s …please..please Post them here or hit with a PM.

I’m miss placed or lost the old output shaft seals ,And Like a complete neeeeewb..failed to write them on my punch list.

This is out of a 2008 700 twin X2 ..800 X2 would be the same ADC gear case.

So id any one knows for certain the seal size’s …please..please Post them here or hit with a PM.