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Replacing Front diff seal Qs

Hey guys, Bike is a 2012 Sportsman 500.
My front diff seal is leaking and I was going to tackle it tonight. But after Looking at it, seems that I have to possibly remove the winch as well as the skid plate , and unbolt the gear box, so I can have some movement to remove the shaft???
There has to be an easier way to replace this seal without dismantling the front end of the bike??
Posted on

Need some help with an 01? polaris xplorer 250 4wd

Have an 01? polaris xplorer 250 4wd here that is a friends.

It has a couple issues rad. fan not working fan itself is ok and works just won't turn on it also was wired to run all the time but was done incorrectly and melted a wire in the connector of the start/reverse override switches. I traced the wire and it's were the fan was spliced into. I found the factory connector for the fan and tried hooking it up but nothing. Not if there's a sensor or a resistor that is bad?

The 4wd won't turn on guessing it's either the switch or solenoid. Switch seems to test fine with a DMM though.

And last but not the least the electric start isn't working starter has been replaced but nothing and the battery ground? wire is lacking a home which may go to the starter?

I'm an automotive mechanic but this is a little foreign to me. Looking for a picture where the battery ground goes.

TIA
Posted on

Do I need a new fuel sending unit???? Help Please.

I've got a 2010 sportsman 500 that ran well for years then slowly started to become more and more difficult to start until no start.

I started by checking spark (it's there) then tracing fuel supply and noticed no fuel exits the fuel tank at top out of the nozzle by the sending unit. See pic.

I can get the engine to start briefly with starter fluid so know most all remaining components are working correctly.

Is there something I'm supposed to do to prime it, rebuild it or is sending unit (way expensive) toast? :cowboy:

Attached Thumbnails
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Posted on

Hello from Las Vegas

Hey all, Just wanted to say hello and introduce myself. I'm new to forums so will most likely be creeping for the first couple days/weeks/months

I work in the automotive and offroad industry making stickers:nerd. Will be at SEMA show at the end of this month as well, maybe I will see a few of you there!

-Jordan
Posted on

1997 Sportsman 500 not switching into High or Reverse

Hi,

I recently purchased an old Sportsman 500 4x4 and it was shifting and driving ok. I attempted to look up fixes on the forums but came up empty. Also my local shop has not solution and doesn't work on ATVs this old.

Now as I get ready for winter plowing it has stopped going into gear. Here is a recap. Would love any help and feedback. Thanks! Paul

- Shifts into Low gear and drives great
- With Shift lever and rod disconnected, I can not operate the trans gear selector with vice grips. It will not go into gear.
- With rear end on jack stand the wheels spin and no noise from trans

Do I need to rebuild or find a used transmission? I've tried hammering lightly on the shift lever on the trans with the shift rod disconnected and it does not move into gear. I thought maybe it was jammed?

Thanks Paul