Category Archives: ATV Repair and Maintenance

Where oh where did my little E-clip go.

I bought a 2000 Sportsman 500 from my cousin, It sat outside over winter and it wouldn’t start the next spring. Now another yr later; after he’s tired of driving around it, he sold it to me.
I pulled the carb, cleaned it. Put in new needle and seat set, pulled the diaphram cover the diaphram looks good, (thank god) but the E-clip has gone missing. Anyone know off hand what size the clip is and what position it goes in? The needle has 5-6 slots on it.

Where oh where did my little E-clip go.

I bought a 2000 Sportsman 500 from my cousin, It sat outside over winter and it wouldn’t start the next spring. Now another yr later; after he’s tired of driving around it, he sold it to me.
I pulled the carb, cleaned it. Put in new needle and seat set, pulled the diaphram cover the diaphram looks good, (thank god) but the E-clip has gone missing. Anyone know off hand what size the clip is and what position it goes in? The needle has 5-6 slots on it.

Where oh where did my little E-clip go.

I bought a 2000 Sportsman 500 from my cousin, It sat outside over winter and it wouldn’t start the next spring. Now another yr later after he’s tired of driving around it, he sold it to me.
I pulled the carb, cleaned it. Put in new needle and seat set, pulled the diaphram cover the diaphram looks good, (thank god) but the E-clip is gone. Anyone know off hand what size the clip is and what position it goes in? The needle has 5-6 slots on it.

2001 xplorer 250 electrical issue

Ok guys I finished rebuilding the top end on the atv and it runs great. Now with a brand new battery on it the push button start doesn’t work nor the headlights, fan or 4×4 switch. I guess my question is, is there a fuse on this atv somewhere that may be bad? At first I thought it was just the switch but it seems that none of the electrical is working other than the neutral and reverse indicators lights. I’m just at a loss and any help would be appreciated. Thanks

2001 xplorer 250 electrical issue

Ok guys I finished rebuilding the top end on the atv and it runs great. Now with a brand new battery on it the push button start doesn’t work nor the headlights, fan or 4×4 switch. I guess my question is, is there a fuse on this atv somewhere that may be bad? At first I thought it was just the switch but it seems that none of the electrical is working other than the neutral and reverse indicators lights. I’m just at a loss and any help would be appreciated. Thanks

New Member, New Wheeler…and a New Problem..

Hey guys. I’m from northern Minnesota. I bought a brand new white 2015 Sportsman 850 with a quick attach full windshield, front lock and ride cargo box, and a rear rack extender for $6,600. I have 243 miles on it at the moment and 11 hours of run time.

I followed the break in by the books. Always used low up to 20 mph. No hard acceleration or quick burst of throttle. After about 200 miles I felt comfortable enough to bring it up to a higher speed (75 MPH) once. The other night I was out on a ride and hit 60 mph and it felt like it hit the rev limiter. Clutch engages at 1650 rpms and at 60 it was around 7500. I looked at the belt and it had no burns or hourglass. At lower speed it has all the power it needs and no feeling of slippage. I think my clutch isn’t fully engaging. anybody else have this problem?.

Thanks in advance

Dylan

New Member, New Wheeler…and a New Problem..

Hey guys. I’m from northern Minnesota. I bought a brand new white 2015 Sportsman 850 with a quick attach full windshield, front lock and ride cargo box, and a rear rack extender for $6,600. I have 243 miles on it at the moment and 11 hours of run time.

I followed the break in by the books. Always used low up to 20 mph. No hard acceleration or quick burst of throttle. After about 200 miles I felt comfortable enough to bring it up to a higher speed (75 MPH) once. The other night I was out on a ride and hit 60 mph and it felt like it hit the rev limiter. Clutch engages at 1650 rpms and at 60 it was around 7500. I looked at the belt and it had no burns or hourglass. At lower speed it has all the power it needs and no feeling of slippage. I think my clutch isn’t fully engaging. anybody else have this problem?.

Thanks in advance

Dylan

2003 Polaris Predator 500 starting issues

I am new to this forum but have been searching on it for days for a resolution.

Here is my problem. I have a 2003 Predator 500 that does not want to start.

-When I turn the key on, nothing is lite not even the neutral light (which its in neutral)
-New Battery with a brand new charge.
-checked all wiring. looks ok.
-I can start the quad from the solenoid when the key is turned on. Once on, the neutral light is on but dims back and forth. So does the rear brake light.
-Once the quad is running, I hit the start button and I can hear the starter engaging in the engine. but when i turn the quad off from the safety switch and then try to start it with the start button, nothing.
-checked all grounds, seem to be good.
-Opened the black bag under the seat and its clean with no corrosion.

Any ideas on what it can be? I am stumped right now.

Thanks

CV joint or U-joint

Any insight would be appreciated. 2005 Sportsman 400 4X4.
Slight side to side wobble in front end when in 4X4.
Wobble could be seen in handle bars and control arms when up on jack stands. Tore down front end completely (was having 4X4 issues) rebuilt hillliard diff, replaced hub bearings and found torn outer CV boot. Tore down CV joint, repacked w/ new grease and new boot. CV joint still seemed stiff, but I thought it might loosen after new grease was worked around fully. All works well, no noises, but still that little side to side wobble. Wondering if the CV joint with the torn boot is bad, or maybe the inner U-joint on the same axle. If just the CV joint I can replace the joint easily. If its the U-joint, I would rather just replace the whole axle since the outer CV had a tear in the boot and could be suspect down the road.
Also, if I replace the axle, can I replace just one, or is it better to replace both half axles together.

Thanks guys!