Category Archives: Polaris ATV How-Tos

Need some advice please

Recently got a 97 sportsman 400 as part of a trade. Believe the motor to be bad. Have someone couple hours away with load of Polaris jet ski motors. Does anyone know if the two are at all simular or could be made to fit?

Any help would be greatly appreciated.

1000 XP Touring Bulkhead Replacement

Just bought a new/used machine –
Very excited!!
Discovered the bulkhead is cracked left side at the shock tower fastening point.
Found the replacement part fine, just cant find recommended attack to replace.
Does anyone have or know of a service manual or pages pertaining to this along with the torque specs etc? It appears any size Sportsman XP model is the same part so the process and specs are the same as well?
Very excited to take the machine out but very concerned regarding the safety factor at this point…
Any help or suggestion would be greatly appreciated at this point
Thanks

1000 XP Touring Bulkhead Replacement

Just bought a new/used machine –
Very excited!!
Discovered the bulkhead is cracked left side at the shock tower fastening point.
Found the replacement part fine, just cant find recommended attack to replace.
Does anyone have or know of a service manual or pages pertaining to this along with the torque specs etc? It appears any size Sportsman XP model is the same part so the process and specs are the same as well?
Very excited to take the machine out but very concerned regarding the safety factor at this point…
Any help or suggestion would be greatly appreciated at this point
Thanks

325 magnum 4×4 A-Arm Bushing Spacers

Newbie here. This is my first Polaris, Bought a 2002 325 Magnum(freedom) 4×4 a couple weeks ago.
I am replacing the A-arm bushings, spacers, & shaft on Friday. When I broke it all down I forgot to look and see which way the "bevelled" side of the spacer goes! :banghead: one side is flush and the other has a bevel to it!!
I believe the beveled side goes inside tward the shaft, am I correct?
Thanks a Million in advance!!!!!

2003 Magnum 330 4×4 Carb Adjust

Newbie here with a question. My 330 would not start, starter fluid/charger jump had it run for 20 sec. Took it apart carefully, took off carb bowl, cleaned out float needle, gas inlet, etc. Blew out with air. Put mostly back together (left plastic panel, seat). It keep running on new reg gas (no ethanol) for 10-12 sec. FINALLY figured out that thats when the battery charger went from STARTING to CHARGE. Checked the battery (.65VDC), so I put in new battery, charged until it was fully charged and she starts right up! Duh!

Now she runs "rough" at higher idle, dies at idle. Restarts up if I give a little gas.

My question is, can someone tell me how to adjust the idle, etc? Using the numbers on this diagram so I really know which screw to adjust?
([url=http://www.partzilla.com/parts/search/Polaris/ATV/2003/A03CD32AA-AB-AC-FB+MAGNUM+330+4X4/CARBURETOR/parts.html]) or provide an illustrated guide? I have the 2003 Service Manual, and the PARTS manual, but they are no help. Model number says I have a Mikuni BST34.

I have searched and searched, and haven’t found one yet…THANKS IN ADVANCE!!

2003 Magnum 330 4×4 Carb Adjust

Newbie here with a question. My 330 would not start, starter fluid/charger jump had it run for 20 sec. Took it apart carefully, took off carb bowl, cleaned out float needle, gas inlet, etc. Blew out with air. Put mostly back together (left plastic panel, seat). It keep running on new reg gas (no ethanol) for 10-12 sec. FINALLY figured out that thats when the battery charger went from STARTING to CHARGE. Checked the battery (.65VDC), so I put in new battery, charged until it was fully charged and she starts right up! Duh!

Now she runs "rough" at higher idle, dies at idle. Restarts up if I give a little gas.

My question is, can someone tell me how to adjust the idle, etc? Using the numbers on this diagram so I really know which screw to adjust?
([url=http://www.partzilla.com/parts/search/Polaris/ATV/2003/A03CD32AA-AB-AC-FB+MAGNUM+330+4X4/CARBURETOR/parts.html]) or provide an illustrated guide? I have the 2003 Service Manual, and the PARTS manual, but they are no help. Model number says I have a Mikuni BST34.

I have searched and searched, and haven’t found one yet…THANKS IN ADVANCE!!