I’m new here, and a DIY kind of guy who has no training in mechanics,
but can do basic troubleshooting and repairs.
My (’95) Polaris Magnum 425 had no spark. After reading many post on here,
I unplugged the two black wires which I found in the wad of wire bundles in the left front area of the four wheeler.
One of these came from the kill switch, the other from a square black electronic module with four wires (the black, a red-on-blk, a white, and a red-on-yellow).
The 425 started fine with the kill switch black either connected or disconnected, but not with the black from the module connected.
What is the square black module that I apparently need to replace; the coil, maybe or pulser?
Hello there, this is my first post. I recently purchased a 2000 Polaris 425 expedition for 700$. They said they were selling it because they switched it into reverse to load it on a trailer and it didn’t switch out. Well after I got it and started investigating I found that wasn’t exactly the case. It was stuck in reverse, but it looks like they sunk the quad. The oil and gas were both white and milky, the frame was packed with mud. The reverse actuator had a big crack in it so I’m assuming that’s where the water got in. Anyway when I jumped the solenoid it started right up, so that was the first good sign. I drained the shit oil and gas, took the clutch cover off and starting fiddling with the shifter and reverse actuator, finally got it into neutral and it shifted through the gears fine. I was psyched! So I put a new gasket on put the clutch cover on filled it with gas and oil started that baby up and went to shift into first, but the shifter is stuck again, took the cover off again, shifted fine, put the cover on, won’t shift. I must be doing something wrong with the cover. There’s a little fork looking thing with bearings inside the cover, I’m guessing it’s the release. When it’s in neutral, which way should the forks be facing? I think if I get this cover on right it should work and after a few oil changes all of the muk should be out and I’ll have a decent quad for cheap! Also the splines on the shifter shaft are shot. I’m assuming the previous owner was trying to force it when they got it stuck in reverse. Is it a hard job to change out? I know the xpedition isn’t a popular model and was only sold for a few years so info is limited on the net. I’m not exactly a mechanic either so try to bare with me. Thanks in advance for any replies!!!
I’m having an issue with my ’15 850 SP, it is really jumpy and lurchy when drive engages, a lot worse than usual. The problem started after a trail ride last week that included a lot of rock crawling. I feels almost like my truck dose when in 4×4 on dry pavement if that makes any sense. any thoughts on this issue? Belt? clutch? something else?
I’m having an issue with my ’15 850 SP, it is really jumpy and lurchy when drive engages, a lot worse than usual. The problem started after a trail ride last week that included a lot of rock crawling. I feels almost like my truck dose when in 4×4 on dry pavement if that makes any sense. any thoughts on this issue? Belt? clutch? something else?
I have been trying to remove the rear axle from my son’s 400 sportsman. So far I have managed to only separate the inner cv joint. No problem, I can put that back together if I ever get the cv cup out of the transmission. I think I damaged the seal too. Anyway, I have been spraying with pb blaster and using a 5 pound slide hammer attached to the cup with muffler clamp and chains. Still no go after 4 days of trying. What the hell else can I try?
Hey guys. So an issue has popped up on my wheeler – the front right head light and tail light won’t work. The tail light shines dimly, but when applying the brake it goes out completely. People have told me this is probably a ground issue – are grounds easy to fix on a 2014 Sportsman 400 HO? I’d rather not take it to a shop and lose $150-300 on an issue that can be fixed at home. If it’s going to be too difficult, I guess I could suck it up and take it in. Any help is appreciated. Thank you!
Hi guys. Recently bought a 1997 sportsman 500 on Craig’s list for 800. It came with a front end loader. The guy I bought it from said its been sitting for about 2 years. It was in pretty rough shape , had some rusting issues. The exhaust was pretty rotted. I got it home and replaced the battery. Rebuilt the carb, flushed out the old gas and got it running. But I’m having issues with either the shifter or transmission. It only drives in low gear. I can’t get it to go into hi or reverse, took the linkage off from the transmission and took off the bellcrank. I put a pair of cannel locks onto the gear on the transmission and tried to switch gears manually while it was running but that didn’t work either. Anyone have any ideas. Any help would be appreciated . Thanks
So I set off this past weekend to replace a torn rear inner CV joint on my 2012 Sportsman.
This is my first real repair job on this quad and everything started off fine…
I removed the wheel, brake, hub assembly and pulled the axle. I cut the boot off and separated the joint to clean out all the old oil. However I can not for the life of me figure out how to remove the inner race off the shaft.
