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Ended up greasing my rear bearings on my 800 last night. Pretty simple process and went well but a guy on Facebook told me a lot of guys are saying bad things about to much grease when you do it. So I guess my question is how much grease is to much???? Im hoping I didnt screw up now.

New to the Polaris world and have a general question. I have a 2018 sportsman 570 and performing 25 hr service. My question has to do with the rear diff/transmission fill plug. What is the hard plastic looking material that is blocking 95% of the fill hole? Is this normal? Why would Polaris do this? I managed to get the oil back into the machine, but what a total pain in the ass! What method are people using to fill this back up? All answers much appreciated, thanks.

Hello all, I am new to the Polaris world, but not ATVs or dirt bikes. So new to this site with my New to me Polaris.

So I just bought a 2002 Polaris Sportsman 700 Twin for cheap as it is in need of repair.
Has been blowing rad fluid out of holding tank. I figured it was a blow head gasket.

Bought it anyways, brought it home and tried to get the rad cap off but it was stuck which was strange. It would turn, but not pull out. I had to pry it out. It seemed to be baked into there. No fluid visible below rad cap. Wiped off the underside of the cap and it was black with what looked like exhaust residue. Wiped out the inside of the tube and was all black as well. So I can only assume it ran like this for a while.

With the cap off, I turned the key to start it to see if it would pump any rad fluid and all I could see was exhaust pumping through and out of the rad cap holder pipe.

So head gasket is blown. https://www.dropbox.com/s/gdbl9zl08t..._3616.MOV?dl=0

In hoping that the head is still ok, I am considering repairs. I cannot start taking it apart for 3-4 weeks, but just thinking about what needs to be done.

I do not know how long it was run like this, but had to be a while due to the black and baked rad cap. So damage could vary, but thinking
- new rad cap
- new thermostat
- gasket kit

Motor runs well, does not smoke oil and no water in oil, unless it was change after it failed, which I cannot verify. Guy said it smokes a bit of blue when first started but stops when warm. Now that could be a choke issue or warn rings.

I ran it for a very short period of time in my garage with the OH door closed and it did not smoke me out and it was a cold engine. So could not replicate the blue smoke when cold.

So I need to check the head and cylinder for warping.
Will check the jug and may do a light hone and new rings pending.

Check the valves, and replace the valve seals at a minimum.

Would the exhaust heat damage the impeller ? I can see it damaging seals, but does not appear to be leaking, but any exhaust heat damage might quickly show up once I start riding, so I will do those seals as well.

I cannot really think of anything else.

I have never worked on a twin cylinder, but have rebuilt dirt bike motors a carb motor for myself. I'm only a backyard mechanic... Haha

I will start going throught the service manual later this week.

Any thoughts ? Any thing else I am overlooking or that I should be paying attention to or replacing ?

Any comments are appreciated.

I’m looking into buys 14” wheels, what width are the factory wheels front and back? I want to try and keep the size differences and not go with the same tire size all around. Looking into putting Pitbull Growler XOR BG2.5 tires all around 27x9-14 on front and 27x11-14 on rear. What’s everyone else running wheel wise for this type of set up?

Secondly if you are running a similar set up how is the ride? 95% of the riding I do is trail riding. I’m open for any input and suggestions.

I’ve been searching through post trying to find what I’m looking for but haven’t really found it.

I got a 2006 sportsman 700 efi and I was plowing snow last night and all of a sudden it died on me. Still had power so I tried to restart but did not hear the fuel pump kick on. I had a previous issue with the relay to I cleaned out the connection and replaced and it had been running fine the past couple months. Could the pump have just gone out?

Hey everybody,
I've owned many ATV'S, dirt bikes, snowmobiles, and motorcycles over the years. Purchased a preowned 2015 Outlander XT 1000 early fall and am excited to start adding some of my own mods. It came with a bag and 4"rack extension on the front, a trunk on the rear, 2" lift kit, rims (that I don't really care for), 27x10-12 ITP Mud Lite tires in the front and 27x12-12 Mud Lite tires in the rear, and an HMF exhaust (which I took of because it was awesome sounding but to loud where I ride). For my own mods I've added the fender flares and OEM hand warmers (love them). I'd like to do some lighting upgrades, and possibly Tracks

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Hey guys,

I'm in the process of trying to figure if I can remove the front shocks without taking the front rack and front body fender off. Does anyone have any suggestions on how to do this 'semi-easily'? I know this may be a redundant question to ask but this 97 Xplorer 500 still has the OEM shocks on it, so ya, they are shot to pieces.. hehehe. Also does anyone have any places that sell decent after market ones for fairly cheap? I don't have a money tree out back so I'm pretty limited on funds. plus I pretty much baby this thing around so it doesn't get dog'd on at all.

I appreciate any instruction and advice you have on process to change them out.

Would anyone know how I can cancel this orange check engine light??

Short of a trip to the dealer 50 miles away, does anyone know how I can cancel the orange light on the top left of my dash??

2003 sportsman 700, fuel is dripping out of the overflow tube so thought might as well throw in a whole carb kit. Any recommendations on brand, All Balls, Moose, Quad Logic or Outlaw. Funny thing is the part pictures on most sellers are all the same picture, so thinking they are all the same kit anyway. Thanks for your time
Also anyone use or have any luck with DynoJet kits.
Donn