I have a 2006 Sportsman 500. I see fuel flowing up/down what I believe is the fuel overflow tube. It is a clear plastic tube (maybe 1/4 inch) that goes up into the area where the speedometer and headlight are located. Is this normal?
I occasionally smell a bit of gas too, especially after a lot of shaking. It isn’t leaking gas onto the ground that I can see, so it isn’t a major leak.
I read some other threads about this maybe being caused by the carb float level? I was hoping to get some background on this problem. I bought my ATV new, and haven’t ever touched the carb. It runs fine, but I was just concerned about the occasional smell of gas, and noticed this fuel running in/out of this overflow line.
Would someone be willing to send me some close up pics of the dash/console/front end/headlight pod/etc? I’ve got and and am trying to rebuild a damaged one. I’ve got the schematics …but real picture showing the speedometer, key location, indicator lights plus the dash and front end plastics would really help! Thanks!
I recently bought a 2013 sportsman 500 ho and a few weeks after buying it the front diff mounts snapped and it broke the front right cv shaft and to totaled the diff.
I’m short on cash right now. Can I just remove both of the front cv shafts bolt the toteled front diff back in and ride it like that until I can get a new diff?
Thanks
will water in my stator cover make my bike break up like it has carb issues.. I had water in my stator cover pull cord unfortunately doesn’t seal to great.. water got into it my bike started to break up rpm gauge started acting up but idle fine
Hi guys. I haven’t posted here in ages. I finally decided to do some maintenance myself on my 2010 550XP EPS. I bought the machine new and before this weekend I’d always carried the machine over to the dealer for service. I did this because I can damn well afford it and gosh darn it I just didn’t want to do it anymore. I’m a pretty accomplished mechanic and build several cars and hotrods over the years including a complete body off 1964 Corvette Stingray.
The machine hadn’t been out of the garage since Deer season in the Fall of 2014. Since it hadn’t been used in awhile I took it with me to Missouri for dove season and to scout someplace for a new deer stand. While up there I noticed some growling coming out of the front diff while in ADC 4×4 mode. It made a grinding sound when decelerating. No sounds in 2WD mode. I thought about taking it over to Polaris, but did some googling on the issue and the consensus is that the front diff needed the oil changed. Well, that’s something I can do here and I wouldn’t have to deal with the hassle of loading it on the trailer and hauling it down there and then picking it up. Bear in mind this machine has always been serviced on time and by the dealer.
So, yesterday I headed off to Lancaster Tx for a jug of diff fluid. The manager let me look at the service manual. Looked pretty straight forward and something I can do in the garage. I gathered up the tools needed (8mm Hex wrench or 5/15" Hex). Removed the bottom front grill for ease of access. Put the drain pan under the machine and went to remove the drain plug. Hmmm. Hex wrench didn’t seem like it wanted to go in very far. Got my 60 yr old fatass under the bike and looked at the plug. Damaged. Crap. Got my brass hammer and tapped the hex wrench into the plug. Friggin thing won’t budge. Tap tap tap with the little brass hammer. No luck. Turned and looked at the Fill plug. OMG it’s effed up too! Also must have been torqued to about 2,000 ft lbs. Then the Hex wrench turned inside the plug. Oh hell no. I took a 50mm torx socket and drove it up in there. No luck. It turned too. Finally put some heat on it from a propane torch and got the fill plug out with a pair of vise grips.
With the drain plug now out it was time to do something with the drain plug. The center of it is now stripped out too. After fighting with it for nearly an hour, I decided the only way it was going to come out is to drill it out and use a 5/16" EZ Out on it. Drilled the hole and now oil everywhere. All over me, all over the floor all over my drill. What a freakin mess. I drove the EZ Out in with my brass hammer and with some extreme persuasion finally got it broken loose.
So now I have to find two new drain plugs and am wondering if the rest of the machine has been abused by the dealer too. For future reference the drain plug size is M16x1.25
Hi, Any help would be great. I have a 2011 that when doing a dry test, there is almost zero compression. When I put some oil in, the compression goes to around 70psi. I’ve read could be rings and was told it was most likely valves. Any thoughts from the pro’s here?
Hi, Any help would be great. I have a 2011 that when doing a dry test, there is almost zero compression. When I put some oil in, the compression goes to around 70psi. I’ve read could be rings and was told it was most likely valves. Any thoughts from the pro’s here?
confused help.. my 2007 sportsman 450 rpm gauge read 280 idling fine ???? don’t understand why it would do that my pcm bad… plus I bought a new pcm like 8 months ago…
