ATV Repair and Maintenance

!999 Sportsman 500 starting problem

I have a 1999 Sportsman 500 and a 1999 Magnum 500, both 4×4. The Magnum starts and runs fine and I use it as a base line and parts trying to figure out problem with the Sportsman.
The Sportsman will not turn over or start. Using a voltmeter and comparing results with the Magnum the problem is with the key turned on and the switch (on-off, headlight switch) in the "on" position but not pushed up to start. On the Sportsman, I’m getting a voltage reading from the cable coming from the starter motor (even when not connected to the starter solenoid) of around 2-3 violts. On the magnum it it zero. The battery, the battery terminal on the starter solenoid and the red wire going into the voltage regulator all read 13 Volts. Also I have disconnected the little red wire coming out of the starter solenoid.
I have swapped out the "on-off headlght switch", the starter solenoid and the CDI unit with the Magnum. The Magnum continues to start and run without any problems and the Sportsman contines to have the same problem.
I also notice if I disconnect either of the fittings on the "on-off, headlight switch" the voltage reading drops to zero. Headlights do not work.
Any ideas? I’m trying to avoid taking the stator out until I’m sure its not something else.
Repair & Maintenance

Socket size for axle nut???

What size socket in metric will fit the axle nuts on an ’06 Rancher? I did a search and about 6 different answers were replied. I have an 1 1/8" wrench and it fit but a little loose, so what metric size would that be?
The search answers were 20mm, 24mm, 27mm, 30mm. Headed to the store and not wanting to buy that many sockets…
Can-Am / BRP

BRP Proposes Nationwide Can-Am Spyder Demo Tour

Valcourt, Quebec, April 10, 2015 – BRP (TSX: DOO) is offering free demo rides across North America. The Can-Am Spyder demo tour will stop in over 150 cities across North America from now through August, providing participants with a free opportunity to test ride 2015 Can-Am Spyder models, including the new Spyder F3.

Demo rides are free and pre-registration is available. Once on site, riders will receive a formal product introduction, followed by a 30-minute demo experience. For a calendar of tour stops and to pre-register for a test ride, visit Can-Am Spyder: 3-Wheel Motorcycles for Touring, Sport-Touring, & Sport | Can-Am Spyder US.

The 2015 Can-Am Spyder demo tour gives consumers the opportunity to experience the thrill of open-air riding. The new Can-Am Spyder F3, the latest model in the Can-Am Spyder line-up is for those who are looking for a lower riding position and centre of gravity, and a muscular design usually found in the cruiser segment. Riders will also be introduced to the first UFit system in the industry. The system provides an innovative way to adjust the riding position to fit the profile, size and preferences of the rider.

“The Can-Am Spyder F3 marks our entry into the cruising-riding segment, which represents a significant growth opportunity for our Spyder line-up,” said François Tremblay, director, Global Marketing, Can-Am Spyder. “We introduced our first Can-Am Spyder vehicles in 2007 and have since extended our line-up to attract different categories of consumers. However, after eight years in that market, we also know what people who have yet to buy a Spyder are looking for. We believe the Spyder F3 will appeal to these consumers.”


Demo tour participants will need a valid motorcycle license, with the exception of California, where only a driver’s license is needed to operate a Can-Am Spyder. For those without a motorcycle license, there will be a condensed, closed-circuit riding opportunity.

The Can-Am Spyder F3 received a Red Dot design award for high design quality in March 2015. Red Dot is an international design competition based in Germany that recognizes excellence in product design.

The Can-Am Spyder line-up now includes four models to meet the desired riding experience of multiple types of riders. In addition to the Can-Am Spyder F3, the Spyder RT touring line delivers the ultimate in touring performance and comfort. The Spyder RS sport line represents the machine for the rider who has a passion for a vehicle with a sport bike riding posture. The Spyder ST sport-touring line represents the optimum combination of comfort and sportiness.

Repair & Maintenance

Recon Axle/Differential Oil Seals Question

Hi,
I am working on our old reliable 2000 Honda Recon. It has given us many years of good service, even stood up to lead foot teenage boy who rode it like there was no tomorrow.
I have run into a question I need help with.
In the image below it shows two #29 Oil seals on the left side.These seals prevent gear oil from getting into the brake drum area.Do both seals install in the differential housing or does one install in the housing, followed by the collar made into the axle, then the second seal?
I replaced axle and bearings couple years ago, missed these oil seals, found my brake drum full of gear oil. OOPs.

Click the image to open in full size.

Repair & Maintenance

2004 TRX 400ex – Top End

Recently purchased a 400ex off craigslist; When doing some basic maintenance, I found that the head cover was missing a few bolts. I ordered OEM replacements for the missing ones. When installing them, I found that the two on the left side (facing forward) would not mate correctly. I also found that the OEM version did not match the one that I pulled out. Also, after looking down into the other hole, is seems to be some sort of reduction. Neither of these seem correct to me. idk what was done before as I was told the engine was stock. With that being said, I was planning on just pulling the head cover off and assessing any potential damage now while I have the bike stripped. Question 1) Is this a simple task (I have a pdf service manual)? 2) Is there anything that you recommend doing while I have the cover off? Replace gasket, valve seals, etc?
Grizzly Electrical & Lighting

660 White Relay

03 660 Griz

Bought about a year or so ago. Not long after had to replace the white relay under the seat. Everything worked fine for a while. Bike sat for several months and then wouldn’t start or turn over. Gave a good charge on the battery so know that’s good. Same prob. Suspected it was the starter relay (or solenoid). Had a brand new spare, so put that on, but problem persisted. Suspect it’s gonna be that white relay again.

Anyone know what the relay does? Trying to search for it but it’s generically listed on parts stores as relay or relay assbly and I can’t find out much about it.

What causes it to go out? Wouldn’t think I should be eating through two in less than a year.

Any ideas would be appreciated. Thanks

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