Author: Forum News

Hey everyone,

Just got a 2004 Sportsman 600 with only 500km... ya thats right KM... I'm up north with tons of mountain riding.

First the plus sides so far... heated grips/thumb, ITP mudlites all around!!!

Now the troubles/changes
Couple things I've had issues with and could really use some help and I suspect some of the issues are from sitting around.

Already had to replace 2 CV boots from splitting after being old.

I replaced all fluids including the diffs

The carb has been cleaned and I would like to know more about the jetting ranges and it adjustments have been made by anyone.

The ITP mudlites are oversized at 26x9R12 fronts and 26x11R12 rears, the issue is the tire rubs the tie rod ends slightly but not enough to cause that much damage to the the tires or anything else. Other issue is slight rubbing when hitting big bumps.... any thoughts???

Tie rod ends are toast and the new 12mm ones are what I'm looking at especially with all the mountain riding. Not sure how they are this bad after only 500km but either way they are being upgraded.

Hopefully an easy fix but the story goes I was out riding this weekend and had a steamy ride with coolant spewing out the reservoir tank. So far I have checked the fan and the bearings seem rough but its still functional when I connect to a battery. There is still power to the fan from the past the bag fuses which I hope means the fuses are still good.

Here is the next confusing thing (stick with me). The temperature sensor/switch in cold condition is conductive and I assume it should read open circuit or very high resistance. With a temp sensor/switch being constantly closed I would assume the fan would run all the time.

So either way... good times so far with this machine and I am sure the fun will continue once I work out the kinks.

Thanks
Bryce

Have any of you guys installed the plow mount and everything by yourself? was just curious if someone who has a good amount of mechanical skills could install one without issues? The dealer install fees kind of scare me a little. Just sounds cheaper if it costs me a couple beers, a pizza, and a couple hours with my dad in the garage versus paying the dealer 3-4 hours in shop time

I have a 2001 Polaris sportsman 500. I just rebuilt the top end of the engine. it did not run before I got it. because the flywheel keeper pin was sheered off.
anyways I got that fixed it would try to start but wouldn't. so I rebuilt the top end and used the head from a 425 new jug new piston and rings also gaskets no valve stem seals as they were good due to the 425 just being rebuilt. also set the valves to spec checked the cam and did all that got a new carb sadly it was for a h.o. version. but I had an extra boot so I open the breather intake a bit make it fit now it idles and idles good but wont run. unless you very slowly rev the engine to higher rpm or it sputters real bad will eventualy rev but its like its running really lean and as you let off the throttle it dies. also getting spark while dying but before you jump and say its the carb I put the old carb on and still doing it but worse. so I ordered a brand new carb o.e.m to spec NOT CHEAP and i'm going to see if that does the trick but if it doesn't witch its prolly not going to any suggestions would be great and please dont ask me if I did something thats already written in the thread PLEASE HELP ME

On my 2014 Sportsman 400HO all lights quit working, front and rear including the brake lights. I cant find a wiring schematic for this model. Does anyone have a schematic or tell me what I should check. Any help is appreciated.

Found out that the stock Polaris tires on the 2017 Sportsman Touring XP 1000 (and others, I guess) are "Not for Highway Use." (But you can license them for "street legal." Huh...)

All the decent trails are a minimum of 20 minutes away by highway. So...I figure my desired riding will be about 25% highway (40 mph and above)/75% trail.

What are your guys' recommendation for tires in this situation?

Scott

Here is my issue

Changed solenoid, arc’d battery reinstalling, no power anywhere, I can pull start w key in on position, but no winch no lights no electric start no gauges nothing. Trying to locate a fusible link but I can’t find one

I’ve got a 2009 Can am outlander, with an 800cc engine that won’t start. It cranks but does not sound exactly correct. The fuel pump works. Fire to both spark plugs. All the fuses seem to be ok. Air filter is clean. It will only start if we pour fuel directly into the butterfly under the air filter. We’ve tried troubleshooting but so far have not been successful. Any suggestions will be appreciated.

Always difficult shifting into reverse or park. While installing the interfaces between the clutch cover and the clutch exhaust tubing I noticed three ground wires were bonded to the top hole of a bracket, right side of quad, that interfered with the shift mechanism. On this bracket are four holes. Two have connectors attached and a third has, on these quads, a bolt with four washers and a rounded nut. I cut the tie wrap on the 10 gauge black ground connector and moved this wire with two other grounds to the hole just below the top mounting hole of the bracket and used the bolt with the four washers to bond the grounds. Correcting the ground bonding moved the 10 gauge wire away from the motion of the shift linkage and no longer interferes with the motion of reverse and park.

During production the line worker found a quick way to bond the grounds but this interfered with the shifting into reverse and park.