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removing body panels

Reading another thread on here, I plan on removing the panels to learn more about the machine and also to apply dielectric grease to all the connections!

What's the best tool to pop out the plastic pop rivets without breaking them or scratching the panels? I have some blue plastic body panel tools from Harbor Freight but they hardly work on my truck.

Also, are all the rivets the same? Or is it like the Torx on this thing, half a dozen different sizes?
Anyone have a good link for rivets that work so I don't buy the wrong ones or have to go to the dealer?
These? https://www.amazon.com/Polaris-Plast.../dp/B00YVZ8QXS

Thanks for the advice and patience as I get started with this thing!
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brakes locking up

I have a 2000 polaris expedition That has sat for a cpl years. I noticed the hand brake lever was very stiff and the brake light was on without applying the brake, so i bled every caliper and it made the handle bar lever feel more normal and worked great for about 20 min of riding then the lever became very stiff again and the front brake locked up not allowing the wheel to move at all. Any help would be appreciated do you think the problem is in that front caliper or in the master cylinder? Where should i start i am lost can the inside of the master cylinder be cleaned other then just the fluid?
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02 Sportsman 700 Carb Questions – Jets & Float Height

First off to those reading this that are willing to help me, thank you. I know this is long so I apologize but I like to include as much info as possible. I bought an 02 Sportsman 700 a few months back and have had no time to work on it. I know that one fix for poor running machines is a new ignition system but I want to find out if I can get this thing running good without the $500 upgrade so I'm in the process of rebuilding the carb and have a few questions. I live in VA and will probably mostly ride in this area, up in WV and possibly up in MI (0 - 3000 ft)

The service manual says for the MAIN JET:
0-6000 ft & above 40*F 162.5
0-6000 ft & below 40*F 167.5
and that a 162.5 was installed stock from the factory in the Mikuni BST 34 Carb

However on the Polaris website if you go to order parts they note that the jet they're selling is a 152.5 or 155.

I bought an aftermarket carb rebuild kit and it included a 157.5 jet and there was a 162.5 in the carb when I tore it apart

1) What jet should I put back in? The 157.5 or the 162.5?

The service manual says for the PILOT JET that a 45 was installed stock from the factory in the Mikuni BST 34 Carb which also aligns with what they're selling on the Polaris website and that's what was in the carb when I tore it apart. In the aftermarket carb rebuild kit, it included a 47.5.

2) Is there any reason to even consider the 47.5 or just use the 45 and be on my merry way?

Finally, the last question: In the service manual it notes in the "Float Height Adjustment" section that the float height should be set between 13 and 14 mm, however earlier in the service manual it notes that it was set at the factory at 14.7 mm +/- 1 mm so.....

3) What height should I set the float at?

I feel like on my 99 Sportsman 500 I had that the "proper" adjustment was for the flat part on the float to be parallel with the float bowl surface but that was a few years back.
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1999 Polaris Magnum 500 starting issues..

Hey guys, first post here but have been creeping forum for a while.
This is my first ATV and I’m learning a lot by doing things myself. I’ve installed LED lights and cleaned up messy wiring and installed a winch, to name a few little projects..

Okay, so my issue at this point is this:
- I press start button, starter spins but doesn’t engage the bendix on flywheel.
- instrument lights all turn off while start button is being pressed.

I can run the ATV by using the pull start.


I have replaced both the starter, and the bendix based on what other people had for issues on the forum.

The battery has also been 12.5v or higher when attempting to start.

Starter solenoid relay was removed, tested, cleaned, and reinstalled.

Now where do I look?!
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Is power steering worth it?

I've never thought about the need for power steering on an ATV. The other week, I test drove a Polaris and an Outlander with PS for the 1st time and I was very impressed. How problematic is this feature and does it require regular maintenance?

I'm perfectly capable of riding without PS and am in decent physical shape. I've been riding a friend's Honda Rincon over some mountainous terrain and have experienced sore shoulders the next day. This is what makes me think about getting the PS, then again, it's a $900 option......:sad
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No start

Hey everyone, I have a 2007 Polaris sportsman 500 EFI 4x4. I went try to start it so I could put the plow on and it wouldn’t start. Stays on a trickle charger so I replaced the battery and spark plugs because it was time to. It started up fine let it run for a bit took it out for short ride before putting the plow on it after like it wasn’t getting any fuel. Check to make sure it was getting fuel and that was all good. It turns over just doesn’t start and I’m getting good spark from the plugs. Any idea what I could look at or do next. Please and thank you.
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Safety recall

Just got this in the mail today. Not even a month old . Glad to know of the issue , but frustrated too. Permanent fix in May.

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