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Okay guys. I’ve been trying and trying to do as much google searching I can. But I just want to make sure I make the best decision possible. Tired of burning through belts. 07 outty 800 30” midlite xxl tires. I have read where these are lighter big tires so a extreme mud clutch kit “shouldn’t “ be needed. Yes I’m guilty of running in high range which I will no longer do in tight trails. I called qsc and they said I should choose the non adjustable kit for 28” setup instead of the 30”. Or if a dalton go with a dbo800 non m I am assuming. From research these are the best choices for my set up, and I’m not willing to buy new primary at all. Most of my riding is trails with mud holes here and there. Clutch kits are near the same cost qsc $240 Ish. And dbo800 $212 ish. Now I see it doesn’t come with a secondary spring where as the mudder kit seems to, its $240 ish.

Again I’m sorry to post another clutch thread but I’m paranoid when it comes to ordering parts and not being sure. Posting a poll but feel free to type thoughts also.

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??

In the dead of winter? Just wondering the best time to buy.

I have a 2012 sportsman 500 HO with a bad foot pedal brake Cylinder. I cannot find a rebuild kit. Does anyone know of a rebuild kit for this or in adequate aftermarket replacement. The OEM part is pretty expensive.

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

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:

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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

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

Hello
New member new machine 2015 outlander 6x6 650 xt, north Vancouver Island