Category Archives: ATV Repair and Maintenance

Issues with my “new” ’87 trailboss 250

I just picked up a 87 trailboss 250 for the girlfriend last week. Checked everything out, drained, flushed, and filled the gas tank, boiled out, cleaned, and reassembled carb. It ran awesome cold (85 degree air temp), would go around the neighborhood just fine, start easy cold with no choke, etc. No problems going around the block.

We took it camping last weekend and the problems began. About 5-10 miles down the road when it would really warm up, it would get very boggy, or act like the throttle was stuck wide open(one or the other). If it would stall out, it would restart 3-5 pulls later holding the throttle open slightly but not want to idle on its own. She would walk away from it and let it cool off, come back 45-60 min later and it would fire right up and run amazing for another 5-10 miles, ending with the same symptoms.

I pulled the carb back apart to verify main jet, pilot jet, all needles, etc were clean and Nothing was blocked.

Where should I start with this? I don’t want to sink $1000 into a $700 machine if I can help it, just doing a little more homework before I tear it down. My dad thinks either the oil injection is screwing up causing problems or the magneto is on its way out and giving weak spark when warm. The (auto) mechanic at my work thinks the rings are weak and the compression is going away when it fully warms up.

My only other experience with 2smokes are my two fan cooled 1988 Polaris 488 fan snowmobiles and Ive never run into problems like this.

Thanks in advance!

check engine light

I have a 2012 sportsman 550 EPS. I moved it out of my shed tonight so I could start installing some lights in the shed. I worked until dark and started the quad to put it back in the shed, the power steering & check engine light came on. i drove it into the shed and shut it off, waited a minute, then started it again and the both lights were off. I looked in the owner’s manual and the check engine light symbol signifies there is an EFI problem and continued use could do serious damage to the engine. I am supposed to go to Jericho ATV Festival on July 31 there is no way a dealer will get it back to me in time. Am I truly risking ruining the machine if I use it for the weekend with the check engine light coming on and off? I am not very mechanical and although any advice will be very much appreciated I will not be able to fix this on my own. I’m pretty much asking if the manual is making it sound much worse than it actually is or if I should adhere to the warning and not use it?

1996 Polaris Magnum 425 4X4 help needed

Recently I purchased my first Polaris 4 wheeler. It is a 1996 Polaris Magnum 425 4X4. I looked it over really good and I purchased it. I got it home drove it around for a couple hours and was very pleased. Next day I took it out and when turning left it started making a loud popping noise along with the handle bars vibrating. I figured it was the right CV joint axle thinking it was binding due to the horrible popping and vibration. I ordered a new complete axle along with new bearings and seals. After installing new parts I took it out and right off the bat same problem. I an very frustrated and need advice on this issue.

1996 Polaris sportsman 400 2 stroke

Hey guys,

Just bought a couple fixer uppers. A 95 and a 96 sportsman 400 2 stroke.
The 95 is brought up to speed and purring like a kitten. However I am having problems with the 96.

Here it is:
– machine won’t start, every so often it will give a small kick as if trying to go, but never does.
– i did a carb rebuild, it’s all good.
– new spark plug and checked for spark – good – plug is BR8ES. Plug is wet- although quite a bit of black oil. I’m sure this is normal with a 2 stroke that hasn’t ran in a while.
– did a compression test. It’s running 90 with the electric start and closer to 110 with the pull start. New battery, new starter.

I’m lost on this one. When I spray fuel into the carb, it sometimes gets a chug, but mostly a small ticking sound, which is strange to me.

Anybody have any suggestions?

PS- im mechanically inclined and familiar with small engines, but far from a genius. So I may have missed something obvious. Let’s hear it.

Thanks

1996 Polaris sportsman 400 2 stroke

Hey guys,

Just bought a couple fixer uppers. A 95 and a 96 sportsman 400 2 stroke.
The 95 is brought up to speed and purring like a kitten. However I am having problems with the 96.

Here it is:
– machine won’t start, every so often it will give a small kick as if trying to go, but never does.
– i did a carb rebuild, it’s all good.
– new spark plug and checked for spark – good – plug is BR8ES. Plug is wet- although quite a bit of black oil. I’m sure this is normal with a 2 stroke that hasn’t ran in a while.
– did a compression test. It’s running 90 with the electric start and closer to 110 with the pull start. New battery, new starter.

I’m lost on this one. When I spray fuel into the carb, it sometimes gets a chug, but mostly a small ticking sound, which is strange to me.

Anybody have any suggestions?

PS- im mechanically inclined and familiar with small engines, but far from a genius. So I may have missed something obvious. Let’s hear it.

Thanks

Final word: 0w40 or 5w50? Sorry in advance!

I know, there’s a oil and lube thread, but it doesn’t seem to get a lot of viewers, and I want to change the oil in my new-to-me 2000 Trail Boss 325 4×2 before I take it on vacation this weekend. Wally World has Mobil 1 0w40 (it says ‘For European Cars – I’m guessing that doesn’t make a difference), and Advance Auto has Castrol 5w50 full synth. Also, for the transmission – can I use Valvoline 80w90 instead of AGL? I’d be fine with using the Polaris lubes, but I can’t find any in my rural area, so I need to substitute, at least this time. Again, sorry for posting this in the maintenance thread (it really is kind of maintenance!), I really appreciate any advice and opinions.

Final word: 0w40 or 5w50? Sorry in advance!

I know, there’s a oil and lube thread, but it doesn’t seem to get a lot of viewers, and I want to change the oil in my new-to-me 2000 Trail Boss 325 4×2 before I take it on vacation this weekend. Wally World has Mobil 1 0w40 (it says ‘For European Cars – I’m guessing that doesn’t make a difference), and Advance Auto has Castrol 5w50 full synth. Also, for the transmission – can I use Valvoline 80w90 instead of AGL? I’d be fine with using the Polaris lubes, but I can’t find any in my rural area, so I need to substitute, at least this time. Again, sorry for posting this in the maintenance thread (it really is kind of maintenance!), I really appreciate any advice and opinions.

Xpedition awd fix gone wrong

Can anyone help me please. I tried the brown wire ground fix on my awd and when I started it up the neutral, reverse lights went out, didn’t fix awd and now will only pull start.. Electric start is not working, awd light not working and light on start button not working. I have never owned a Polaris so I don’t even know where to begin looking.

Xpedition awd fix gone wrong

Can anyone help me please. I tried the brown wire ground fix on my awd and when I started it up the neutral, reverse lights went out, didn’t fix awd and now will only pull start.. Electric start is not working, awd light not working and light on start button not working. I have never owned a Polaris so I don’t even know where to begin looking.