Category Archives: ATV Repair and Maintenance

2013 Sportsman 500 HO Front Drive Shaft Problems

I recently bought a 2013 sportsman 500 ho. The other day my brother was riding it going 50 mph he said it slowed down quickly and smelled like burning rubber. I took a look at it and the drive belt was shredded. I replaced the belt and rode it for 5 minutes and it seemed fine. The next time I went to ride it I noticed a weird clanking noise when going over 10 mph I looked at it and the front driveshaft was really lose then I noticed that the mounts foe the part the drive shaft goes into in the front were snapped so that entire part is loose. Also the axle to the front right wheel is disconnected. What should I do?

I’ll take pictures when I get the chance. Thanks

2013 Sportsman 500 HO Front Drive Shaft Problems

I recently bought a 2013 sportsman 500 ho. The other day my brother was riding it going 50 mph he said it slowed down quickly and smelled like burning rubber. I took a look at it and the drive belt was shredded. I replaced the belt and rode it for 5 minutes and it seemed fine. The next time I went to ride it I noticed a weird clanking noise when going over 10 mph I looked at it and the front driveshaft was really lose then I noticed that the mounts foe the part the drive shaft goes into in the front were snapped so that entire part is loose. Also the axle to the front right wheel is disconnected. What should I do?

I’ll take pictures when I get the chance. Thanks

Oil temp sender spec

i have a 2001 325 magnum with oil cooled engine I am looking for the spec at what temp it turns the cooling fan on, my doesnt come on.The fan works when I jumper the sender connector,Iam thinking the sender is bad.i have a temp gun so if i know the spec temp I can check it.Thanks for any help

EPS light Relay

2012 Sportsman Xp850 Eps..

EPS Light went on… inspected electric circuit…
The morons at Polaris did not figured that an ATV is going to see water and dirt..
Look at the relay..

And worst !! the relay is tape upsidedown !! to make sure water will stay there..

I cleaned with acid.. and diĆ©lectric grease… reposition relay…now ok

EVERY connector on this bike has to be loaded with dielectric grease..

Front prop shaft roll pin alternative

I recently removed my front prop shaft to replace the universal joints and I was wondering if anyone has tried something other than using a roll pin to hold the shaft into place. Some had suggested using a grade 8 bolt with a nylock nut and some locktite. Was just wondering what others have used to get some ideas.

2012 Polaris Sportsman 850 XP EPS

Fixed Voltage Regulator

2012 Sportsman XP850 Esp stopped charging.. and esp light on….
Testing the stator.. OK
No volts comming out of the regulator..
decided to open the regulator by removing all the sealing rubber..

Easy to remove be careful not damaging the board..
Then.. COROSION !!

That corosion came from the yellow wires by capilary action.. can you imagine..
the connector of the stator had humidity Inside.. so put full of dielertric grease in there..

I did an extent research to find if a component was toasted.. tested the diodes and SRC’s.. all good..


be carefull here… plastic insulators have to return at there right place !!
So.. found nothing wrong except the corosion that should have created short circuit…
Cleaned with electrical contact cleaner and a tooth brush.. reassemble and .. tada.. all perfect now…

Closed the unit cap with silicone… make sure its sealed tight

New member/owner in need of clutch help

I recently bought a 2007 sportsman 450. On test drive all was well but after I got it home and put some time on it out on the trails it started to creep and I am unable to move the gear selector while running. It shifts fine when it’s cold but every time it gets warmed up it does the same thing. I adjusted the shimming behind the secondary clutch or the "driven" so that when it idles cold it does not turn with the primary but it still does the same thing when it warms up after riding it around a little. Any thoughts help or ideas would be greatly appreciated. I should also say that the previous owner said he put a clutch in it and cleaned the belt new and the belt is not Polaris. He did give me the old Polaris belt with it.