Quantcast
Jump to content

Recommended Posts

Posted

So, I got this 07' Polaris Outlaw 90 in the shop to rebuild top end and transmission. Replaced all bearings and gears in the transmission. Replaced cylinder and piston with brand new parts. Put the engine back on the frame and fired it up. Started great, but had a taping sound in the lower crank case. pulled the flywheel cover off and found the flywheel was wobbling and hitting the stator. I then replaced the stator and flywheel with brand new parts. Timing is all set on the timing marks now, but when I turn it over it kicks back when it fires and ends up stripping the starter idler gear. I've replaced the starter gear once already and now have to replace it again. Is it possible that the timing marks on the flywheel are off or maybe this flywheel is not for this exact model? Thinking of advancing the timing to try it, but don't want to keep going through idler gears.

  • 1 month later...
Posted

I have now gone through 4 starter idler gears on this bike. I've checked and rechecked timing marks. Nothing seems to explain what is happening. I read somewhere that the temp sensor is bad and causing the timing of the spark to be off and backfire. However, I have not been able to locate any kind of temp sensor on this particular bike, and I see no way to adjust the timing of the spark. Anyone come across this before? I cant keep going through these gears for $30 each.

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.



  • Similar Forum Topics

    • By WeeBee
      I'm looking at buying a New "CarryOn" 5'x8' Trailer with the Ramp Gate and Mesh Floor from my local Tractor Supply store ! Anyone have any experience with this Brand of trailer to share ?? Thanks!
    • By LashinWheeler
      Hello all, I have a 2006 Polaris Sawtooth with no spark. It has a dead battery but with a jump pack on it, it will still not Spark. Plug is good, Throttle ETC is not closed, Stator pick up coil seems to Ohm out in the correct range, Unsure how to properly check the CDI. And when ignition is on the Neutral and reverse light come on but after cranking just the neutral stays on. 
       
      Any help would be great,
       
      Thanks!
    • By Shorty51
      Good morning, I am new to the forum. I'm 75 years old and love getting ATVs back to usable condition. I particularly like the 2006-2009 Arctic Cat 250 Utility. I currently own 6. The 2006 I am working on only has reverse and low gear. The "drive shaft" in the transmission is completely stripped where the high gear would mesh. Has anyone on here replaced the shaft. I'm told I have to split the case. I was hoping that someone on here could let me know how hard it will be. I already have it stripped down to where the shaft coming in from the clutch side is the only thing left. I was hoping I could just remove the driven clutch and drive it out from there. Directions say different. Any help would be greatly appreciated.
    • By flyinbrian365
      View File 2018-2019 Polaris Sportsman 850/1000 service manual
      2018-2019 Polaris Sportsman 850 / 1000 – Official service manual Resource
      📌 This thread is dedicated to the factory service manual for the 2018 and 2019 model year Polaris Sportsman 850 and 1000 ATVs.
      What's Covered:
      This service manual covers complete OEM factory procedures for the following models:
      Polaris Sportsman 850 (2018–2019) Polaris Sportsman 1000 (2018–2019) Polaris Sportsman 1000 XE / Trail / High Lifter / Touring variants (where applicable) Manual Contents Include:
      Engine service & specifications (ProStar 850 & 1000 single-cylinder EFI engines) Fuel system diagnostics & EFI troubleshooting Drivetrain, transmission, and AWD service procedures Electrical system schematics & wiring diagrams Suspension, steering, and brake system specs Clutch adjustment, belt service, and CVT procedures Torque specs, fluid capacities, and maintenance schedules Diagnostic trouble codes (DTCs) and service tool usage Intended Audience:
      This resource is for owners, shade-tree mechanics, and professional technicians working on 2018–2019 Sportsman 850/1000 platforms. Whether you're doing routine maintenance, diagnosing a fault code, or tackling a full engine rebuild, this manual has the factory-spec procedures to get it done right.
      Submitter flyinbrian365 Submitted 06/04/2026 Category Polaris ATV  
    • By Admin
      View File 2013-2016 Polaris RZR 570 service manual
      Download the 2013-2016 Polaris RZR 570 service manual PDF for complete factory repair, maintenance, troubleshooting, and diagnostic procedures. This comprehensive Polaris RZR 570 repair manual covers all major systems including engine service, EFI fuel injection, transmission and clutch repair, drivetrain maintenance, suspension, steering, brakes, electrical troubleshooting, wiring diagrams, torque specifications, and factory maintenance schedules.
      Designed for RZR owners, mechanics, trail riders, racers, and DIY enthusiasts, this factory-style service manual provides detailed step-by-step instructions and diagrams for maintaining, troubleshooting, repairing, and rebuilding the Polaris RZR 570 side-by-side UTV.
      Topics covered include:
      Polaris RZR 570 engine repair
      EFI fuel injection diagnostics
      CVT clutch and transmission troubleshooting
      Drivetrain and differential service
      Suspension and steering maintenance
      Brake system repair
      Electrical troubleshooting and wiring diagrams
      Oil change procedures and maintenance intervals
      Torque specs and factory service data
      Polaris RZR diagnostic procedures
      Popular related searches:
      2013 Polaris RZR 570 service manual PDF
      Polaris RZR 570 repair manual
      RZR 570 wiring diagram
      Polaris RZR torque specs
      RZR 570 clutch problems
      Polaris RZR maintenance schedule
      Polaris UTV factory service manual PDF
      This Polaris factory repair manual is ideal for owners looking to maintain, troubleshoot, repair, or upgrade their RZR 570 for trail riding, recreational off-roading, hunting, racing, and utility use. Whether you're performing routine maintenance or a complete rebuild, this manual provides the factory information needed to keep your Polaris RZR 570 running at peak performance.
      Submitter Admin Submitted 05/30/2026 Category Polaris UTV  
×
×
  • Create New...