Author: Forum News

I own a 1996 425 Magnum 2x4. I recently rebuilt both drive and driven clutches because the bushings were worn out. The Polaris drive belt has 40 hours on it.

A problem that developed before I rebuilt the clutches was that the drive clutch would contact the inside of the outer cover. I thought that rebuilding the drive clutch may cure this. It didn't.

I've owned this quat for 15 years and the drive clutch contacting the inside of the outer cover happened gradually over the past three months. The hit makes a mark at the top of the cover where the outer edge of the drive clutch contacts it.

There is no crankshaft endplay.

I checked center to center distance, it was spot on. 10.5 inches IIRC.

I used a Polaris clutch alignment tool, they were well within spec (after rebuilding).

The belt is at the new spec, and the free play is in spec.

Now when I had the inner cover removed, I put a level on the end of the crankcase and the engine seemed to be pitched down on the PTO end a fair amount. This would agree with the fact that I can make the noise go away if I put a piece of fuel hose as a spacer between the inner cover and the engine crankcase, in effect pushing the inner and outer cover outward at the top. I can do the same thing if I apply light pressure on the top of the outer cover just over where the drive clutch is.

I'm at a loss. The quad gets perhaps 20 hours of use per year around the yard dragging a cart.

Could it be bad (aging) rubber engine mounts?

I own a 1996 425 Magnum 2x4. I recently rebuilt both drive and driven clutches because the bushings were worn out. The Polaris drive belt has 40 hours on it.

A problem that developed before I rebuilt the clutches was that the drive clutch would contact the inside of the outer cover. I thought that rebuilding the drive clutch may cure this. It didn't.

I've owned this quat for 15 years and the drive clutch contacting the inside of the outer cover happened gradually over the past three months. The hit makes a mark at the top of the cover where the outer edge of the drive clutch contacts it.

There is no crankshaft endplay.

I checked center to center distance, it was spot on. 10.5 inches IIRC.

I used a Polaris clutch alignment tool, they were well within spec (after rebuilding).

The belt is at the new spec, and the free play is in spec.

Now when I had the inner cover removed, I put a level on the end of the crankcase and the engine seemed to be pitched down on the PTO end a fair amount. This would agree with the fact that I can make the noise go away if I put a piece of fuel hose as a spacer between the inner cover and the engine crankcase, in effect pushing the inner and outer cover outward at the top. I can do the same thing if I apply light pressure on the top of the outer cover just over where the drive clutch is.

I'm at a loss. The quad gets perhaps 20 hours of use per year around the yard dragging a cart.

Could it be bad (aging) rubber engine mounts?

I own a 1996 425 Magnum 2x4. I recently rebuilt both drive and driven clutches because the bushings were worn out. The Polaris drive belt has 40 hours on it.

A problem that developed before I rebuilt the clutches was that the drive clutch would contact the inside of the outer cover. I thought that rebuilding the drive clutch may cure this. It didn't.

I've owned this quat for 15 years and the drive clutch contacting the inside of the outer cover happened gradually over the past three months. The hit makes a mark at the top of the cover where the outer edge of the drive clutch contacts it.

There is no crankshaft endplay.

I checked center to center distance, it was spot on. 10.5 inches IIRC.

I used a Polaris clutch alignment tool, they were well within spec (after rebuilding).

The belt is at the new spec, and the free play is in spec.

Now when I had the inner cover removed, I put a level on the end of the crankcase and the engine seemed to be pitched down on the PTO end a fair amount. This would agree with the fact that I can make the noise go away if I put a piece of fuel hose as a spacer between the inner cover and the engine crankcase, in effect pushing the inner and outer cover outward at the top. I can do the same thing if I apply light pressure on the top of the outer cover just over where the drive clutch is.

I'm at a loss. The quad gets perhaps 20 hours of use per year around the yard dragging a cart.

Could it be bad (aging) rubber engine mounts?

Good Morning Gentlemen.

I have a 850 Sportsman XP HO and think that maybe it'll be cheaper for me to do my own grease fittings and oil change. Now, i'm not a mechanic, but i do know a little basic stuff.

My question is.....i'd like to know how many and where the grease fittings are and do i have to get oem specific oil?

Good Morning Gentlemen.

I have a 850 Sportsman XP HO and think that maybe it'll be cheaper for me to do my own grease fittings and oil change. Now, i'm not a mechanic, but i do know a little basic stuff.

My question is.....i'd like to know how many and where the grease fittings are and do i have to get oem specific oil?

https://www.atvtrader.com/listing/20...Fire-119759926 pretty good right?

Hello, I just got into 4 wheelers this past Memorial Day, I've had some older Polarises and they've never failed to put a smile on my face. I currently own a 2014 Ace on Terryx Tusk 27s. It's the 325 but it sure is fun. I'm going to sell it and get either a 900sp or a 900xc. I can't stop looking at track kits and Scramblers though. My wife has already said yes to the Slingshot, so I'll probably sell the Ace for the down payment and get the bigger Ace later. The kids have asked for a 2up instead and I really like them being involved. Oh the decisions (Yes, I know the simplest solution is to by them all.) The problem I run into is my nearest Polaris dealer is also the only CanAm dealer in the area and I can't get anyone there to have any type of conversation where everything is shit and I should buy a CanAm. They even sell Honda and Suzuki...anyway, I wanted some unbiased opinion, because I've found just as much info online about CanAm defects, and the only people who rag on Polaris are usually CanAm owners or advocates. I like recreational riding with the kids and some moderately aggressive trail riding. I know I love power, but I tend to like the Sportsman more than the Scrambler. The Ace is just a bucket of fun. I'll be reading, y'all take care.

Hello, I just got into 4 wheelers this past Memorial Day, I've had some older Polarises and they've never failed to put a smile on my face. I currently own a 2014 Ace on Terryx Tusk 27s. It's the 325 but it sure is fun. I'm going to sell it and get either a 900sp or a 900xc. I can't stop looking at track kits and Scramblers though. My wife has already said yes to the Slingshot, so I'll probably sell the Ace for the down payment and get the bigger Ace later. The kids have asked for a 2up instead and I really like them being involved. Oh the decisions (Yes, I know the simplest solution is to by them all.) The problem I run into is my nearest Polaris dealer is also the only CanAm dealer in the area and I can't get anyone there to have any type of conversation where everything is shit and I should buy a CanAm. They even sell Honda and Suzuki...anyway, I wanted some unbiased opinion, because I've found just as much info online about CanAm defects, and the only people who rag on Polaris are usually CanAm owners or advocates. I like recreational riding with the kids and some moderately aggressive trail riding. I know I love power, but I tend to like the Sportsman more than the Scrambler. The Ace is just a bucket of fun. I'll be reading, y'all take care.

Own 2012 850 sportsman touring and just got a 2018 sportsman 570 sp. (wife’s)
I understand the different features of the 570 vs 570 sp. just curious what sp stands for????? My dealer didn’t know.
Thanks for the forum!

I’ve got a 1 month old 2017 Sportsman 850 and while greasing it today I noticed a line hanging down. Just wondering if this is some kind of breather line or if it’s disconnected from somewhere? Couldn’t see anything obvious without pulling plastics off and I had to leave for a few days without pulling it all apart

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