Category Archives: Polaris Sportsman

[Newbie] Hose from crankcase to nowhere

Hello riders,
I am new to Polaris Forum (and to ATVs)

Under minimal research and curiosity, I was able to to get 2012 Sportsman Touring 500 HO. I was surprised how much premium 2UP takes (just to keep ex happy and yet she never tagged along).

ATV run fine, was clean so i simply happily took it on trails.
But on maintenance, i got stumbled a bit.

I changed oil (a bit unusual when comparing to cars) but I found loose hose that got me very worried. There is a hose by crankcase drain plug that goes to nowhere, and I fear that it may such in moisture or worse water into engine:

When removing seat I found that there is a broken connection so hose doesn’t connect to airbox (relatively obvious fix) but I noticed piece of aluminum foil covering port in carburetor.

I wonder if that’s where the house from under the has to go.

Lastly, obligatory picture of how my ride looks like:

[Newbie] Hose from crankcase to nowhere

Hello riders,
I am new to Polaris Forum (and to ATVs)

Under minimal research and curiosity, I was able to to get 2012 Sportsman Touring 500 HO. I was surprised how much premium 2UP takes (just to keep ex happy and yet she never tagged along).

ATV run fine, was clean so i simply happily took it on trails.
But on maintenance, i got stumbled a bit.

I changed oil (a bit unusual when comparing to cars) but I found loose hose that got me very worried. There is a hose by crankcase drain plug that goes to nowhere, and I fear that it may such in moisture or worse water into engine:

When removing seat I found that there is a broken connection so hose doesn’t connect to airbox (relatively obvious fix) but I noticed piece of aluminum foil covering port in carburetor.

I wonder if that’s where the house from under the has to go.

Lastly, obligatory picture of how my ride looks like:

05 700efi electrical issue sitting duck.

Hello everyone. I am having issues with my quad. 05 700 twin efi. I was using the winch one afternoon and the battery light flashed on the gauge. So I stopped using winch. Revved up a lil bit and then died. No power. Battery tested good. Stripped down and inspected wires etc. my fuse block on far left 20a fuse has no power on either side. Kill switch is on run position. I have one hot wire at ignition switch nothing else works. Got new switch and key and still same thing. If I jumper wire the one side of that fuse slot everything lights up etc. is this an issue that has happened to someone else. I’m at my whitts end. Been reading all sorts of stuff on here and havnt found anything that helped. Any advice or help is greatly appreciated. Thank you for your time.

2003 polaris overheating

I have a 600cc 2003 v-twin polaris sportsman ATV and the fan doesnt run but it ran for about 3 seconds in the morning when i started it for the day now it wont run idk how to wire it so it will run but its making the coolant boil and overflow…. the oil isnt milky so its not leaking into the head i can ride for 30 mins before coolant squirts everywhere…. rad isnt plugged either thermostat looks good i tested it in 200 degree water and it opens up idk what is going on… does a running fan help dramatically cool the engine or does it really not need to run?

2004.5 Sportsman 400 parts identification/fittment

Hi guys, I recently bought a 2004.5 sportsman 400 with some parts missing, and I was hopping you could help me identify what I need and where to get it the cheapest. I attached pictures below. I looks like I need the radiator guard and bumper support? Would radiator guard from a 2004 sportsman 600 work? I would like to mount a winch in the front too, preferably somewhere low, in case that changes the parts I will need. thanks.

I also need screws for the belt cover, those are missing too, do you know what size those are?

Thanks for your help.

2004.5 Sportsman 400 parts identification/fittment

Hi guys, I recently bought a 2004.5 sportsman 400 with some parts missing, and I was hopping you could help me identify what I need and where to get it the cheapest. I attached pictures below. I looks like I need the radiator guard and bumper support? Would radiator guard from a 2004 sportsman 600 work? I would like to mount a winch in the front too, preferably somewhere low, in case that changes the parts I will need. thanks.

I also need screws for the belt cover, those are missing too, do you know what size those are?

Thanks for your help.

2013 Sportsman 500 cv joint

Hey guys. I need to replace my inner rear cv joint and am wondering how to get the joint itself off the shaft. there doesn’t seem to be a circlip holding it on, but some sort of spring clip that may lock into place when pressed on. It is a 2013 Sportsman 500. Thanks for any help.

1997 front wheels won’t engage

Hey pep’s, I have a 1997 sportsman 500 4×4. I’m currently at a lose as to why my front wheels won’t engage when in 4wd (button pushed to on).
I’ve been reading about it and it seems that most peoples speedos are the issue, however my speedo works just fine.
I can’t find a wiring diagram anywhere.
I popped the cover off in front to see the electrical board ad did find a loose wire (just hanging) on the left side. Its a purple wire tied in with 3 other wires. Can someone tell me where that goes? What else should I look for?

1997 front wheels won’t engage

Hey pep’s, I have a 1997 sportsman 500 4×4. I’m currently at a lose as to why my front wheels won’t engage when in 4wd (button pushed to on).
I’ve been reading about it and it seems that most peoples speedos are the issue, however my speedo works just fine.
I can’t find a wiring diagram anywhere.
I popped the cover off in front to see the electrical board ad did find a loose wire (just hanging) on the left side. Its a purple wire tied in with 3 other wires. Can someone tell me where that goes? What else should I look for?