Honda UTV Forum

Good diagnostics, glad you got it up and running.

I havent had a lot of success with JB weld on exhaust , doesnt like the high heat, but it will hold for a while, if still having problems they make putty for exhaust, also doent hold up well, the constant jaring of the machine loosens it and it falls out. Not much help, but that is my expierience.

Tanks do get nasty, being plastic helps a lot, not rust ot corrosion, and they clean up very easily. Good job getting it going and painting the racks, coming along nicely.

Hey! So, I got back on the project this week. I've started up a part time small engine repair gig and it's been keeping me busy! Anyhow, I got the ol girl running pretty good. I cleaned out the fuel tank and while doing so, realized that was 90% of my problem all along.🤦🏼‍♂️ Can't believe I overlooked that. Tank was FILTHY! Pretty much was mud at the bottom and once I got that flushed and added fresh gas, she fired right away. Now to buy some front tires and she'll be ready to have some fun and be put to work. Painting the racks and front bumper also. Will have them put back on next week. (Busy this weekend 🥵)

View File 2003 Polaris Ranger 400-500 Service Manual 2003 Polaris Ranger 400-500 Service Manual Submitter rgeiser Submitted 04/18/2024 Category Polaris UTV  

I ended up welding a bombardier 400exhahst onto it ... And then it still backfired , I discovered more holes up near the head, I'm going to use some high heat jb weld to patch them

Most handlebar switches can be dismantled and cleaned.

My uncle bought a Baja 250, 2006. Knew there was no spark since the get go. He don't know anything about quads so is getting me to help him try to get it running... Battery is bad so I connected battery charger to it to crank it over , cranks over well , but no spark .... Lights and everything work fine , but with each crank over using the e start switch , the display reads 999 888 777 666 ... Right down to 000 and repeats itself . He managed to get a parts bike , I changed over the CDI and the coil and the stator from the parts bike and there was another black box by the voltage regulator I changed over ... I used my multimeter to confirm as much as I could works , it's hard without knowing which wires are which , and I cannot find any diagrams online for this bike ? Do you think it could be the Killswitch? There's so many wires coming from there I don't know where to start . Also I should mention it appears the fan on the front of the bike has been taken off (the wires have been cut too ) If this bike sparked it would run . The previous owner said he parked it one day and it just wouldn't start after.

Thank you for your insight. I will check on the oil in the sump when I get a chance.

Awesome are ATV's allowed there too?