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By Scott Sirr
I need to figure out how to clean/fix or replace my neutral switch assembly On my 2008 Yamaha big bear 400 as generally the neutral light doesn’t come on when it is in neutral. To get it to come on I have to wiggle the foot shifter and hold it in just the right spot.
I have googled it and can’t find much on the 400’s. I can’t find a service manual online and the parts manual is super vague.
I think it is in the right side engine cover area, but not certain.
Any help would be great. thanks
By Mike Johnson
Does anyone know what the 3rd item is behind the battery on this ATV ? I know 1 is the, solenoid1 is the CDI box, what is the 3rd.
By colin james
View File 1996-2000 Polaris Sportsman 335/500 Service Manual
This is the factory service manual for the polaris sportsman 335 & 500.
You can download the section you need or download all of the chapters for the complete manual
Submitter colin james Submitted 10/19/2018 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!
By Steven Alter
I have a 2018 450 and the digital gause has started flashing on an off while driving. The backlit also goes on and off. It is worse when I hit the gas. The battery died a few weeks ago and I jumped it but its been fine until last night. Called the dealer and showed them a vid and they recommend replacing the gauge and its like 600 bucks. The machine has less than 100 hours on it. I would really hate to have to change it out. also the unit sometimes has trouble starting. Any ideas?
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