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Does anyone know what the part number is for the foam air filter that fits on the neck of the black plastic intake of a 1996 Polaris Sportsman 400 2 stroke? A mouse got in there and chewed mine all up. Also if anyone knows how to get a replacement drain plug that goes in the bottom of the silver air intake (which is just below the black plastic intake just below the seat), I need that as well. The mouse chewed on the 4 grey X connectors that hold the plastic plug in place and it fell off. One more question, it would seem an air filter should sit inside the silver metal intake, but my atv doesn't have anything there. I've searched and searched, but can't seem to find the right parts for sure.

I do have an electronic service manual for the Sportsman, but it seems that many of the pictures are of the Sportsman 500 and not he 400 2 stroke that I have. Any help would be greatly appreciated! I love my 2 stroke and would like to get it back up and running.

Hey guys, Leland here.
As stated when I joined this forum, I'm 63, retired and we are now living in Puerto Vallarta Mexico. We just brought our new Outland Max 1000 into Mexico. Because of parking (very narrow) city and town streets (again very narrow and crowed) we thought a ATV would be the way to go. They are street legal and many people ride them. Hell, we've seen as many as 12 people on one, a small one at that.
Anyway, question is speed. Everything here is metric. Here is how the speed limits break down: (Keep in mind they are only a suggestion.)
45kph=28mph, 60kph=37mph,80kph=49mph and 100kph=62mph.
How long can the outlander run at the higher speeds? Normal speeds on Highway 200 is between 45kph and 80kph. Many slow downs are due to traffic, speed bumps (they love their speed bumps) and stop lights so the distance isn't more than, I would 5 miles at a time.
I am new to the ATV thing and never have had one before so heckle me lightly.
Thanks guys
Leland

Using most of the troubleshooting methods mentioned on other threads-
1.Stock Stator checks out fine as per OLDpolaristech thread (replaced w/ Chinese stator from ebay just in case) still no spark
2. Checked safety switches (handlebar on/off and tether)
3. Coil checks good except 0 zero voltage coming from CDI (replaced w/chinese coil from ebay just in case) still no spark.
4. Checked CDI as per OldPolarisTech recommendations. Black wire disconnected. (replaced w/chinese CDI from ebay just in case) still no spark.
The only tangible thing I have is 0 zero voltage at coil wire from CDI when trying to start.
Any Ideas?

This thread was started to share a couple of tricks that may have been mentioned elsewhere.

I've got a couple of Sportsman machines, use them in ranch work. They are well taken care of but they earn their living. We never submerge or abuse them but we do work them hard, spraying brush, catching cattle, checking fences, etc.

Overheating was a regular problem each summer.

The biggest culprit has always been seeds (grass and weeds) getting into the radiator fins. As you know it's a chore to pull the rad off, not to mention that tiny seeds are next to impossible to clean out. I've used compressed air, water hose, a/c coil foam, acid bath, heat, etc. You name it, I've tried it. None of it is quick or easy. Seeds don't like to turn loose.

The solution is two-fold:

1) Remove the radiator and get it as clean as possible. Put radiator back in and zip-tie a 12x12 pleated a/c filter directly onto the front of the rad. Each day blow the seeds off the filter by shooting compressed air through the front grill. You can order these filters by the case for a few bucks each. As long as you don't get them wet they last a long time.

2) Do the old automobile trick and pull out the thermostat. Because there is no gasket you will have to cut the guts out of the thermostat with a Dremel tool, leaving the hollow housing with the ring seal intact. That part is cleaned up with the brush wheel on your shop grinder to remove any burs. Put it back in the machine and you're good to go.

We have had plenty of days in the high 90s to low 100s, working the machines hard, and the fan only runs part of the time.

NOTE: Make sure to order a new thermostat for putting back in the machine when the weather cools off. Otherwise the engine won't warm up properly.

This has been a HUGE time and trouble saver for me.

Hope it helps some of you!

Stattor checks good@ 30+ volts AC, voltage regulator good 14.5 volts, 12.5 v on battery w/ATV off, 14.5v at terminals when running. If you remove the ground wire while ATV running, it dies. Why?

New to these boys, couple of questions for those who know. Looking at 2 A 2007 Sportsman 500 2300 miles $3400.00 and a 2014 570 750 miles $4200.00. Both show no signs or ruff lives. What concerns me is both have what sounds like valve problems, very light tap tap. both swear regular maintenance. IF that is or is not true. How much damage is likely on both. How often do they require adjustment. thks for any advice suggestions. Kalel

I have Kinda Bearclaw HTR and I put a lot of miles on them and the rears seem to be wearing out.

The indentation on the molded rubber has worn down to wear its almost smoothed over. Im thinking of replacing the rear tires.


So how often do you guys change tires? Seasonally?

Hey I've been looking at the kits available on the website and been real curious how well the engines hold up with any of the kits? Also which kit would be best suited for me? I have a 14' 650XMR. I don't race my bike on a regular but when we go to Busco we all like to have fun and make a couple passes on their track. Mostly I just do trail riding and a lot of mud. I'm not out for most power possible I prefer good clean reliable power.


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How is the ride, handling, performance? Is it worth the extra money for the Fox QS3 shocks? If you have one, or have ridden one, lets hear what you have to say about it.