Anyone experience your machine acting like it is stuck in 4 wheel drive when it isn’t? After driving a distance, it abruptly kicks out & all is normal. Any ideas? It is a 2003 Sportsman 500 H/O

Anyone experience your machine acting like it is stuck in 4 wheel drive when it isn’t? After driving a distance, it abruptly kicks out & all is normal. Any ideas? It is a 2003 Sportsman 500 H/O

Hi all. First time 4 wheeler owner here, and not the handiest tool in the box. Our machine was well used and needed some work which was done by a local shop who returned it ‘in fine working condition’. We got it back, rode it gently for about 15 minutes (had new top end), and it promptly died. Looked it over and found radiator hose was detached and engine was leaking coolant around head gasket. So back to the shop it went. They said the hose must have blown off because of the overheating, not the other way around, and the overheating was caused by a fan malfunction. Got another new head gasket. Having already blown our budget, they gave us the quick/cheap fix of jumping the fan switch so it would run all the time. Fine. Back home, we fire it up and the fan is running like a champ. We ride for 5 minutes, then jump off to make sure the fan is still running (don’t want to blow another gasket) and sure enough it is not. Back to the shop. Now we have to get a new fan and thermal sensor. All fixed this time, really. Back home, ride for 15 minutes, and everything seems nice and warm but still no fan. Is this normal, or are we risking blowing another gasket? The radiator is 150 at the top, the front of the engine 150-180, and the exhaust header >300. We stopped riding there so as not to do more damage before we figure out what normal is. At what temp or after how long of moderate riding should that fan (on a new temp switch) kick in? Thanks!!!

I’ve got an 95 xplorer 400 4×4. The other day i started it and just got moving and it dies on me, starter would not spin the engine and the rope was extremely tight. I took the recoil off and the belt cover off and I’m able to rock the crankshaft back and forth but can’t to a full revolution. I stuck piece of wire in the plug hole and the piston is moving with the crank. I’m getting ready to pull the engine and while taking off the exhaust there was a bunch of small pieces of metal right off of the cylinder. Any ideas of what I’m getting ready to find? Another question is how to I get the clutch off and the backplate that sits behind the clutch off of the engine. I’ve looked around and can’t find anything about removing engines so any would would be appreciated. Thanks

I’ve got an 95 xplorer 400 4×4. The other day i started it and just got moving and it dies on me, starter would not spin the engine and the rope was extremely tight. I took the recoil off and the belt cover off and I’m able to rock the crankshaft back and forth but can’t to a full revolution. I stuck piece of wire in the plug hole and the piston is moving with the crank. I’m getting ready to pull the engine and while taking off the exhaust there was a bunch of small pieces of metal right off of the cylinder. Any ideas of what I’m getting ready to find? Another question is how to I get the clutch off and the backplate that sits behind the clutch off of the engine. I’ve looked around and can’t find anything about removing engines so any would would be appreciated. Thanks

Parked my 2006 Sportsman X2 500 EFI HO a week ago and was running fine. Went to start and would not start. It tried to fire a few times and eventually I gave it some throttle and it started, but I would not rev up and when I let o the throttle it died.

Now it will not fire at all. There is a new spark plug and spark looks strong. I poured gas down plug, and still no fire. Compression seems fine using thumb test.

I followed manual instructions and a no error codes. That said, nothing seemed to happen, will you see anything if there a no codes?

What to check next???

Parked my 2006 Sportsman X2 500 EFI HO a week ago and was running fine. Went to start and would not start. It tried to fire a few times and eventually I gave it some throttle and it started, but I would not rev up and when I let o the throttle it died.

Now it will not fire at all. There is a new spark plug and spark looks strong. I poured gas down plug, and still no fire. Compression seems fine using thumb test.

I followed manual instructions and a no error codes. That said, nothing seemed to happen, will you see anything if there a no codes?

What to check next???

Hello,
I’m hoping someone here can help me. After much reading and buying, I am stumped. I have a 2003 Sportsman 90 that won’t start. At this point, I have replaced the battery, stator, CDI, coil, and the Brake Sensor switch.
I have jumped over from the battery to starter and it will turn over (red to red/white) at the relay box, which clicks when I do. The machine will still not start. I should mention I have no tail light either.
This leads me to believe that it is either the electric start switch or one of the 2 kill switches. Is there a way to bypass these or test these to isolate or eliminate these as the problem? I do have a multimeter. Also, if these check out ok what would be my next move, short of crying ?:)
Thank you in advance,
Scott

Hello,
I’m hoping someone here can help me. After much reading and buying, I am stumped. I have a 2003 Sportsman 90 that won’t start. At this point, I have replaced the battery, stator, CDI, coil, and the Brake Sensor switch.
I have jumped over from the battery to starter and it will turn over (red to red/white) at the relay box, which clicks when I do. The machine will still not start. I should mention I have no tail light either.
This leads me to believe that it is either the electric start switch or one of the 2 kill switches. Is there a way to bypass these or test these to isolate or eliminate these as the problem? I do have a multimeter. Also, if these check out ok what would be my next move, short of crying ?:)
Thank you in advance,
Scott

Hello. I am having an issue with my front strut deal sleeve. It doesn’t seem to be seated in my strut causing it to wiggle. Is this a problem with the strut or is it the seal sleeve itself? And how would i fix this? Please help!