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Got a 04 Sportsman 500 that wasnt running- owner said it needed a stater and a new battery. It ran rough (been sitting out in the weather for a while). A friend and I started by adding a new battery and it would start barely with the choke and his hand over the air-filter. I decided to install the new battery in the holder on the side. we had it on the rack because the old on was still in the bike. I tried to be nifty by turning the battery to put the terminals in an easier spot to get to, but forgot to reverse the cables too. In a sentence, I reversed the positive and negative on the battery like a dummy. When we discovered my mistake and corrected it, we turned on the bike, but the display did not light up and the key did not turn on the starter. jumping the solenoid worked the starter, so we thought the solenoid just burned up when I reversed the pos and neg... new solenoid and no difference. what have I burned up? Also, the shifter does not seem to do anything in the trans. it slides back and forth like its stripped in the trans. any help would be appreciated!!
I think the biggest issue right now is the electrical.
By Christian Brindle
I have a 2000 Polaris Sportsman 500. A year or so ago we got it running after replacing the kill switch. It ran great but after some use for a couple months it got a flat tire and for some reason we just forgot about it and it sat for some time. Before it sat i replaced the gas cap, fuel filter, fuel pump, petcock, battery, starter relay, oil and oil filter. I recently went to start it and it started so quickly and without choke or throttle but the ATV wouldn't move till about 1/4 throttle and it wasn't really a smooth ride until 1/2 throttle. it also would bog out randomly after you came to a stop and sounded like it was getting too much fuel. I cleaned the carb and adjusted the air/fuel screw to 1 3/4 turns out. I also messed with the idle and the throttle cable adjuster up on the handlebars. It's safe to say it now runs worse than when i started working on it 2 days ago. It takes more effort to get started and bogs out idling after about 30 seconds. I tried adjusting the idle but every time i do it'll get to a sweet spot but after driving it down the driveway and back the idle will go up and down to the point where i can't put it in gear because the gears will grind. Any thoughts or ideas would be greatly appreciated. Thanks
I'm working on a 2018 Sportsman 570 and found in the service manual that there are two different torque methods for the head bolts depending on whether the bolts are silver or black. Well, silver bolts came out of my engine and I'm going to be replacing them with new bolts, however the parts fiche doesn't specify bolt color or that there is even an option!?!
Has anyone on here been through this before and can offer insight??
View File 2005-06 Polaris Sportsman 400 450 500 Service Manual
2005-06 Polaris Sportsman 400 450 500 Service Manual.
Full ATV service manual
Submitter flyinbrian365 Submitted 02/18/2019 Category Polaris ATV
I've never done this before but after reading a few thread I decided to check my valves for the first time and to my surprise it was much easier than I thought.
My bike is a 2005 Sp 500 HO.
I first pulled the seat and the right side panel off, and that's it! It wasn't too bad to get at.
Next I pulled the spark plug out and removed both the head cover ( 8-8mm bolts)
then the side cam cover (5-8mm bolts).
Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
Next I turned the engine over with the pull cord untill it was at TDC of the compression stroke.
The best was to tell that your at TDC of the compression stroke is to rotate the engine until the
timing marks are parallel to rocker cover gasket surface.
The cam sprocket locating pin will be facing upward directly in line with the crankshaft to camshaft center line.
Now fine adjust by looking into the timing hole in the recoil cover and line up the upside down "T" on
the flywheel into the center of the hole.
Now using a feeler gauge, slide the .006" (.15mm)blade between the top of the valve and the bottom of the adjuster and adjust accordingly
To adjust, Loosen the locknut (10mm) and check clearance with a feeler guage. Clearance should be .006" (.15mm) for both, intake and exhaust valves. Turn the adjuster with a stubby flat blade screwdriver untill the proper clearance is achieved then tighten the locknut (5.8-7.2 ft. lbs) while holding the adjuster in place with the screwdriver. Re-check the clearance with the feeler guage one last time and re-assemble the covers (72 in.lbs) and plugs.
The only thing that i noticed was that I had to clean and silicone the side cam cover other than that I found the whole process rather simple.
I'd give it a 4 out of 10 on the skill level scale.
I hope this helps!
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By Alan Callison
I just got a 2004 Yamaha that needs some work.Its got wet brakes on the front that Im trying to get working.My problem is the brake lever.This the lever on it now.On the master cylinder it has a cable in it that has the wire that fits in a slot inside the lever itself but this lever isn't made for that.I dont know if whoever had it before didn't know what they were doing or what but its the wrong lever for this machine. Can someone point me in the right direction here? I looked at the Yamaha website and the schematics only show a part that looks like this one here. Again,I have a 2004 Yam 400 Kodiak 4x4 and its an automatic model. BTW,the master cyl. was bone dry. I was gonna change out the rear brake shoes and when I went to pull off the wheel,get this, each wheel stud had 2 different sized washers holding the lug nuts to the wheel rim. The stud holes were so worn out it had worn away the base of the studs and the holes were the size of quarter! Im lucky someone didn't die while riding this! A word to the wise.Pay attention to what you buy.Look carefully and keep a keen eye out. This was my fault because it was the 1st ATV Id ever bought and I didnt notice alot on this machine so I guess I count myself lucky in that I didnt get hurt nor did anyone else who rode it either.
If you are looking for a used ATV for sale, where do you look? I know ebay and craigslist have used ATVs for sales and then sometimes you find local trade publications where they list used ATVs. I was looking online and decided to list out some websites that sell used ATVs. If you know of any additional websites or sources to look for or buy used ATVs, please post as a comment in this topic.
eBay Motors - usually has a good selection of four wheelers, ATVs, and Side by Sides and offer seller protections
Craigslist - usually has more local ATVs, but be careful as there are no seller protections
ATV Trader - has over 130k ATVs listed by private sellers
ATVSoup.com - new and used ATVs for sale
WantAdDigest - Shows local listings of ATVs for sale
ATV.com - List new and used ATVs for sale
When buying a used ATV, make sure you do your research and find out the book value of the ATV, look over the condition of the ATV, and as for verification of ownership. Be careful who you buy from and get the ATV checked out by a professional dealer or repair shop if you are baying a high price.
Watch our for VIN numbers that are scraped off, this is usually a sign that the ATV was stolen.
By Jacob Blocker
I got an ATV from a guy that ran out of time rebuilding an eiger 400. He put a nerma Piston and rings in. I finished it up and it smoked like a train. I took the head off and honed the walls and it looked like the rings where on the walls, but it smokes just as much. I'm confused what's wrong with this thing.
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