Category Archives: Polaris Sportsman

1996 Sportsman 500 Exhaust

Was looking to put on a new exhaust on my sportsman, and was looking for some suggestions. Should i get a full exhaust or just a slip on? and some suggestions on what to get also, stock exhaust just doesn’t do it for me anymore.

Thanks,
Travis

2000 polaris xpedition 425 ?

I have a polaris 425 with the 5 speed 9 on it. It has a issue in every gear when first giving it throttle it acts like the clutch slips a bit tthen will act like it catches and goes fine. Is thus a clutch Iissue or carb issue? How do I adjust the clutch

2003 Sportsman 400 Float Bowl Device

There is a plastic part about the size of a nickel on my 2003 Sportsman 400 (Model A0CH42AA, S/N 4XACH42AX3B793892) that attaches to a nipple on the carburetor float bowl at one end and the device’s other end has a hose that just hangs loose not connected to anything. The device itself is not shown on any manuals or drawings that I can find. The connection from it to the float bowl rotted off. I snipped a piece of the hose off of the exit end and used it to re-attach the device at the float bowl. It doesn’t seem to matter if this mystery device is connected or not. Can anyone tell me what it is or what it does?

Needing some measurements

In my quest to make my 02 sportsman better, and finding good parts for the year being next to impossible. I am trying to Frankenstein my front end [emoji106]

So if anyone with a 2005 – 2010 sportsman 600, 700, or 800 could measure a front a-arm, it would help me out tremendously before I spend more money buying parts…..

So what I need….I would like the width of the frame side, meaning from front to back, width between ends where the bolts go in ( hopefully around 11" )….. and then the length, or from outside of the frame side tube to center of the ball joint hole like the picture I will post. In the picture the measurement would be roughly 13 3/8".

Thanks for any help

Sportsman 500 seat

I found a guy selling a seat for 08 and older, I have an 09 and need a new seat I went on to a parts cache and the part numbers are the same from 11-05 but he has pictures of the bottom and looks a little different could anyone could help me out if needed I could get his pictures and take pictures.
Any help is appreciated
Thanks
Mike Munro

06 Hawkeye 300?

I have a 06 hawkeye 300 4×4. Didn’t see a section specified for the hawkeye so i figured its pretty much a sportsman 300. I just picked the machine up about a week ago. Had been sitting for about a year. New gas, battery, clean out the carb, all the jets. I got it to run intermittently with some carb cleaner. It runs when it wants to. I changed the spark plug and before i did it i checked it for spark and there was none. I changed the plug and checked again and still no spark. I had it running about 5-6 times for about 45 seconds each time so it did have spark at one point. What should i do? There any fuses ect?

inner rear axle joint

Went riding last weekend and broke the right rear inner joint on the axle the parts that I need are the cup that goes on to the gear case, the knuckle that goes on the shaft and the shell that holds the bearings on the knuckle does anyone know the part numbers to any of these or the actual name of the parts also can I buy them separate or does it come as a kit??

what is this plug in for

So I have taken the old girl apart to replace the gas float to stop the gauge from blinking and I found a plugin with nothing connected. I have attached a picture. Nothing there before just wondering what it is for…..

Thanks
Fakker

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2012 sportsman a-arm

just changed the bushings and shaft in my 2012 sportsman 500ho, I am the second owner and it has 3000 miles. The right hand side it tight no play at all, the passenger side has forward back play about half an inch. Is it possible its the wrong arm? the new shaft was the same size of the old shaft

2000 sportsman 500 clunking in transmission when turning hard left

Hi guys. I have a 2000 sportsman 500. I have been trying to get rid of the clunk in the rear end when I turn left. I have replaced both rear cv axles and changed the fluid while I was there. No major metal on the magnet. All the bushings look good and i greased everything. The noise is even worse now after I did all that! I used polaris brand fluid. The noise only appears when making a slow speed turn left in 2wd mode. Haven’t tried it in 4×4 because it sounds so bad I just parked it. The noise stops if I turn hard right and doesn’t happen at all going straight. I had the wife drive it in a slow circle and put my hand on the rear case. It seems to be coming from inside there. Any ideas? Google hasn’t been very helpful on this specific issue. Thank you!!