i was just moving my sportsman around the yard and it just stopped moving all of a sudden and started making whining noise i took the belt cover off hoping it was just the factory belt finally give out but it was not. The primary doesn’t turn with the motor like it used to in the past times I’ve had the cover off. I’m thinking the transmission has givenout. I use it for mudding and it has just over 100 hours any thought and help will be most appreciated.

I have a 99 Sportsman 500 HO.

After 20 or so minutes my lights start flashing and I blow bulbs. ($200 and counting) I replaced the voltage regulator and it still happened. I replaced the stator. Still happens. So I connected the meter to the cigarette lighter port and ran the motor for 30 minutes and put plenty of load on the circuit. Voltage stays >10V and <16V. Looked good. No flashing. Hmm… So I started running it at high RPM like I would if I was cruising down the trail. After a few minutes I saw the voltage spike over 20V (max scale on meter). Of course I blew out my light bulbs. Doh!

So it appears the voltage regulator can’t handle high RPM’s and can’t smooth out the signal. I would suspect the transistor is failing to switch fast enough. Probably due to heat. This is my second voltage regulator but I did buy a cheapo on Amazon. Is there a quality difference? Is there a place I can buy from that has quality components inside the regulator?

I have a 96 sportsman 500 that was running fine yesterday till I hit a mud hole and it died. I got it cleaned up and running now but it will only start if it’s in gear and dies if I shift to neutral. Any ideas?

07 sportsman 500 that seems to get extremely hot before the fan kicks on and sometimes the hot light comes on this problem even occurs in the winter while plowing and the exhaust pipe on the right side behind the plastic body panel also get really hot just wondering if the two issues are related? My guess is not but just looking for some other opinions .

I have a 2005 sportsman 500 6×6. I’m doing a middle axle rebuild but I couldn’t get the chains apart. I had enough play in the axles to slip the chain off but going back together that axle will not move enough to get the chain back on.

Anyone know how to seperate the chain? I found the master link on each one and removed the locking tab. but I can’t get the pins to push out using a punch. Is there a Special Polaris tool for this? or does anyone have a YouTube video somewhere?

I have a 2005 sportsman 500 6×6. I’m doing a middle axle rebuild but I couldn’t get the chains apart. I had enough play in the axles to slip the chain off but going back together that axle will not move enough to get the chain back on.

Anyone know how to seperate the chain? I found the master link on each one and removed the locking tab. but I can’t get the pins to push out using a punch. Is there a Special Polaris tool for this? or does anyone have a YouTube video somewhere?

Have the dreaded ECM problem and need to buy a new one. Seems like the Surepower ECM’s weren’t that much better than the junk ECM’s from the recall. Last resort is the stealership but I’d rather find one online somewhere. These ECM’s seem pretty rare. I see a couple on Ebay that say they are only good for the ’05 and ’06 models. What changed from ’06 to the ’09 model?

I got a deal on a 2001 scrambler 50 that needs some work. Right now it won’t start. At first it wouldn’t even fire and no pressure was coming out the exhaust. I was finally able to get it to fire for me and run for a second by disconnecting the exhaust pipe. It must be clogged? It will run for a few seconds every time it is turned over but dies out. I checked compression and it is about 120. It has good spark. It had mixed gas in it when I got it so I am assuming the oil pump wasn’t working. I took the carb apart and cleaned it out as best as I could. The carb was set at 1.5 turns and I put it back that way. Wondering if it might need to be rebuilt or if there is something else I can try. Also is it possible to clean out the exhaust pipe?

Hi I’m Jason I have a 2011 Polaris sportsman 500ho it is making a popping and clicking noise when you drive it I put it neutral and pushed it you could hear the noise when machine is off sounds like dry bearing or something not really sure

Hi I’m Jason I have a 2011 Polaris sportsman 500ho it is making a popping and clicking noise when you drive it I put it neutral and pushed it you could hear the noise when machine is off sounds like dry bearing or something not really sure