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Hello all. I have a 2002 Sportsman 500 HO with only 350 miles. Won it with one ticket during a DeWalt promotion at local hardware store. Yep it's DeWalt yellow. Job got in the way of fun so parked it. I've rebuilt carb, running fine but OEM bushings dry rotted. Changed all fluids. Need some direction on which Mfg/bushings to use. Thinking about jccapri but can't figure out what they are made from. There is an abundance on bushings available but not sure of quality and lifespan. Not everyone is up front about material used. Need some direction where to look. Thanks much. DeWalt Special

I have a broke axle that is stuck in the diff. Can't figure out how to get the piece out????

I have a 2009 Polaris Sportsman 500 high output. Has around 2200 miles on it. Engine runs fine. Transmission is bad. The transmission is out of the Quad currently. Everything is intact and available. Looking to sell the whole quad located in Western Massachusetts

Ok, so this is the second time this has happened! 2004.5 Sportsman 600 Twin. The first time was just over 2 years and 60hrs ago. Parked and shut the machine off for lunch and white smoke came out under the hood. No power to anything. Got it home and found that the key switch had shorted from the v-reg wire to the brown ground wire. Melted the ground wire all the way to the connector under the hood. Replaced the ground wire and switch ($85 from Polaris), tested everything I could think of and moved on.

Fast forward to last weekend in the middle of the trail. Key switch started acting up. It would start but as soon as I let off the switch it would stall. If I held the switch between run and start if would stay running and after a while I could let go and ride the machine. Until it stopped on the trail and I got a puff of smoke from the headlight pod. No power to anything. Pulled the pod and found the ground wire melted again. Towed out and home. Same issue. Switch is shorted and the brown wire melted.

I have included photos of the switch. I cut the part around the plug off the switch for the photos. I really don't want to go through this again. I plugged in a new switch and I have power. Once I get the ground wire replaced I will fire it up and test the charging system. Any suggestions would be helpful!

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Lookin for a front wheel bearing kit for my 98 xplorer 300. I need it today or tomorrow and unless i can find it locally im' screwed. Any suggestions?

I ended up with two of these little projects.
I took the plastics off and replaced the carb and air filter and toss a little premix in ( the oil pump is disabled but I need to check into that more) and it fired right up.
Today I changed the gearbox oil and put the body back on.
NO SPARK.
I get started cranking but I have no spark.
If I understand correctly the fact the starter is running means its not the: key, kill switch safety think, break switch.
Where to from here.
I pulled the CDI from the other bike to see if it would help but didnt.
Thanks all - new to forums and new to polaris.:grin

Hey guys had to take the radiator off the highlifter to clean it really well before I install the rogue radiator cover. What the the easiest way to bleed all the air out of the coolant system? Thanks.


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Hey guys had to take the radiator off the highlifter to clean it really well before I install the rogue radiator cover. What the the easiest way to bleed all the air out of the coolant system? Thanks.


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I was wondering if there was a ignition wiring diagram for the 2002 325 trail boss?

I was wondering if there was a ignition wiring diagram for the 2002 325 trail boss?