There’s quite a bit of slack in the linkage of my machine mainly between park and reverse, which causes the tranny to slip. When it happens, I have to play with the shifter to get it into gear. Does anyone know how to adjust or tighten the linkage? Thanks.

Does anybody have any suggestions on what brand of cv boot to buy? I was going to order from rocky mountain ATV and the reviews for there boots were terrible. Everybody said they crack in the first year. Any suggestions?

First post from a 4 month lurker. Thanks to all the great info in this sight I’ve found all the info I’ve needed so far.

Bought an ’05 Sportsman 800EFI for a song because previous owner wasn’t very handy and couldn’t afford to have some needed work done. Full fluids change, brake bleed, new front wheel bearings, new style flex exhaust, exhaust wrap, heat shielding, new plugs and she’s been running like the beast it is until recent heat wave.

I knew these models suffered from some heat issues and have experienced it running hot, especially climbing steep hills in mid 90’s we’re seeing now. Nothing dangerous but definitely hotter than I want. I installed a new tstat and thermistor after testing existing ones and not happy with results, added quadovator tstat housing and temp gauge along with fan override switch, which both helped piece of mind and cooling….but want even more cooling for better longevity and one last step before I replace fuel pump to help with "hot gas tank fuel pump failure" syndrome I’ve had two times.

After doing rad flush and refill with water and water wetter, I was cleaning the radiator and realized the ecu is placed in what I consider the worst possible place…right in front of radiator blocking air flow. My thought is to fab a couple of aluminum brackets to rotate the ecu up and out of the way of the rad. Then cut the fake grill off the plastic trim piece and fab up some metal mesh on it to get better airflow in from the top (currently only the lower section has mesh). To anyone who has done this or has opinions on any issues this may cause I’d appreciate your input. Also, do I need to maintain ground for proper function?

Thanks for your help,

JCIII

Attached Thumbnails

 

First post from a 4 month lurker. Thanks to all the great info in this sight I’ve found all the info I’ve needed so far.

Bought an ’05 Sportsman 800EFI for a song because previous owner wasn’t very handy and couldn’t afford to have some needed work done. Full fluids change, brake bleed, new front wheel bearings, new style flex exhaust, exhaust wrap, heat shielding, new plugs and she’s been running like the beast it is until recent heat wave.

I knew these models suffered from some heat issues and have experienced it running hot, especially climbing steep hills in mid 90’s we’re seeing now. Nothing dangerous but definitely hotter than I want. I installed a new tstat and thermistor after testing existing ones and not happy with results, added quadovator tstat housing and temp gauge along with fan override switch, which both helped piece of mind and cooling….but want even more cooling for better longevity and one last step before I replace fuel pump to help with "hot gas tank fuel pump failure" syndrome I’ve had two times.

After doing rad flush and refill with water and water wetter, I was cleaning the radiator and realized the ecu is placed in what I consider the worst possible place…right in front of radiator blocking air flow. My thought is to fab a couple of aluminum brackets to rotate the ecu up and out of the way of the rad. Then cut the fake grill off the plastic trim piece and fab up some metal mesh on it to get better airflow in from the top (currently only the lower section has mesh). To anyone who has done this or has opinions on any issues this may cause I’d appreciate your input. Also, do I need to maintain ground for proper function?

Thanks for your help,

JCIII

Attached Thumbnails

 

My sons Outlaw 90 has a high rev CDI box on it for racing. The Quad starts and revs some but if we try to give it anymore power the quad shuts off and wont restart.

Is this a bad CDI box?

Hi folks,
I have a 97 Polaris sportsman 500 which has a problem with 4wd. When I bought it a few months a go the wires going down to the 4wd hub on the right side had been ripped out which I managed to repair but when I push the 4wd switch I get nothing.
I have tested the switch operation for continuity with a meter on the grey and grey/white wires and I am getting a good circuit (0.03ohms) when the switch is pressed so I know that is good. I have had a look at the wiring diagram but I’m struggling to see how it all works.
There are 4 wires to the switch, the grey + grey white for the switch operation, brown for ground and there is also a yellow wire. I assume this should be ignition voltage but I get nothing there and on tracing the wire through the harness it joins into the grey/white wire!?
Any ideas on this would be greatly appreciated.

Just got a new engine on my 14 sportsman 850xp due to water in the old engine…now to be safe I snorkled it weird thing is now it won’t tell me what gear I am in also the eps light went on but eps is working fine….snorkels are great but anyone know why i can’t see the gear

Attached Thumbnails

 

My wifes 05 trail boss has some sort of ignition/electric issue. After about 1/2 hour of riding the atv will die. The first couple times it does this, it will fire right back up when you turn the ignition. Eventually it gets to a point where it goes completely dead. When you turn the ignition nothing happens like the battery is disconnected. Even though lights and brakes still have power, but no gear indicator light. Once it cools down it fires right back up. I originally changed the ignition switch thinking there was an issue. Still had problem so changed ECM, $200.00 later still does the same thing. Could this be a CDI or solenoid issue? ATV runs great before this starts. Any advice would b GREATLY appreciated, Thanks

So I get a 2003 Sportsman 500 4×4 which had been long neglected (long story short) and i decide to change all fluids because it’d be cool to have it to play around. I get to transmission fluid, i remove the plug, clean it (lots of metal shavings on magnet, of course) and when i went to place it back, it just wouldn’t get tight (i was using a torque range, set to 14lbs). So i say, that’s weird, and i remove the plug, only to find out the actual thread was disintegrating and coming apart :motz: Please don’t let me be the only one that this has happened to :inv: I’m not taking it to the dealer $$$$$ and i’m hoping this won’t be an expensive do it myself fix :pedro:
Any ideas??
Thanks!!!

So I get a 2003 Sportsman 500 4×4 which had been long neglected (long story short) and i decide to change all fluids because it’d be cool to have it to play around. I get to transmission fluid, i remove the plug, clean it (lots of metal shavings on magnet, of course) and when i went to place it back, it just wouldn’t get tight (i was using a torque range, set to 14lbs). So i say, that’s weird, and i remove the plug, only to find out the actual thread was disintegrating and coming apart :motz: Please don’t let me be the only one that this has happened to :inv: I’m not taking it to the dealer $$$$$ and i’m hoping this won’t be an expensive do it myself fix :pedro:
Any ideas??
Thanks!!!