2017 polaris sportsman 450 ho lazy starter

[huanchaco]

Living in northern Peru there is no chance of a cold start but i noticed my 450 starter was becoming sluggish with more than 20,000 miles on the engine.

Besides the camshaft missing the decompressor ball it was becoming a scary thought to get it started on a remote beach.

After pulling the starter apart i found worn out brushes,one of them barely contacting the collector. Of course, no polaris parts to be found here but automotive

brushes can be adapted and shortened to fit, file and sand here and there and soldering the copper mesh wires in place, now i have a starter that spins strong and

cranks as new again. My next problem will become the chinese fuel injector I ordered. Instead of the Bosch 2521068 ( 30 lbs/hr) you get the Bosch 0280158091

from Aliexpress (22.9 lbs/hr) which is a Chrysler 3.5 l engine injector, or is it a remanufactured one?? Difficult to tell, but it starts on the lean mixture side on a cold start,

after that it runs pretty good. To make sure,a friend going to the US is bringing the right injector.

[huanchaco]

24 minutes ago, huanchaco said:

Living in northern Peru there is no chance of a cold start but i noticed my 450 starter was becoming sluggish with more than 20,000 miles on the engine.

Besides the camshaft missing the decompressor ball it was becoming a scary thought to get it started on a remote beach.

After pulling the starter apart i found worn out brushes,one of them barely contacting the collector. Of course, no polaris parts to be found here but automotive

brushes can be adapted and shortened to fit, file and sand here and there and soldering the copper mesh wires in place, now i have a starter that spins strong and

cranks as new again. My next problem will become the chinese fuel injector I ordered. Instead of the Bosch 2521068 ( 30 lbs/hr) you get the Bosch 0280158091

from Aliexpress (22.9 lbs/hr) which is a Chrysler 3.5 l engine injector, or is it a remanufactured one?? Difficult to tell, but it starts on the lean mixture side on a cold start,

after that it runs pretty good. To make sure,a friend going to the US is bringing the right injector.

The Bosch 0280158091 is actually from the Ford cyclone 3.5 L engine, the Chrysler one is the 233 (27 lbs/hr) my bad.

[davepo]

Whoa!!  20000 miles on a 2017?  You get around!! :-)

My girlfriend has a 2017 450 HO, we bought it new for her when I bought my 570 Sportsman (2017 also)...hers has 245 kilometers on it now LOL...still has the little rubber nubbies on the original tires, quad isn't even broken in yet.

But anyway, if you have 20000 miles on yours, it means they are very good, reliable quads!

Have you had any other problems with it?

Dave

[huanchaco]

Hi Dave, actually it has 41000 km,(25000 miles) . I bought it from a company that plants mango and oranges for export in northern Peru a year ago after

it served it's field and commuting service for 3 years. It still looks quite new and appears to have been well maintained,but mostly the engine and gear box.

Suspension,sway bar and moving parts had been neglected so I had to make a mayor overhaul,mainly lubrication and bushings. The clutch weights had carved

their way sideways and clutch bushings replaced with small piston pins cut to size. I have rebuilt and filled the gaps with spacers and better fitting parts made from

motorcycle scrap. Now I have a still good working primary clutch and Aliexpress sent me a clone for 200 bucks that needs some tweaking but works good.

I am amazed at the design of the Fuji engine,which also makes the Subaru. It's 2 valve,2 bucket under the camshaft is virtually non maintenance and the conrod

big end and coated piston should be good for 50000 miles with proper oil intervals. On the other hand having been a motorcycle guy for 50 years and all around mechanic

In Peru and Holland, a Polaris quad is a high maintenance hobby but it's worth every minute you hit the beaches and dunes. Most people here stick to their atvs for

there is no other transportation besides mototaxis (3 wheeled unstable 2 people carriers) and chinese junk atvs.

Rob, 68

Los Organos, Piura,Peru

[davepo]

Rob, I totally respect your ability to fix things with any available parts "lying" around, and use your ingenuity to re-purpose them and alter them to make them fit and work.  I wish I had more of that ability.

I only use my quad for 3 or 4 outings per year...hit the trails in the deep bush, in northern Ontario.  I have yet to do anything to my 570, except I've changed all the fluids already (engine oil twice).  I have approx 1200 kilometers on it (in 4.5 years), so I should be good for another 100 years approx hahaha.  The only thing I've noticed so far is that one of the grease nipples on the lower rear A-arm is stripped and came out when I pulled the grease gun off of it, I will have to fix that.  I love this quad!!

Take care buddy, nice talking to you, hope you're doing ok in this crazy times!!!

Dave

[huanchaco]

It's crazy times indeed Dave,never thought Einsteins quote " 2 things are infinite : the size of the universe and people's stupidity,but not sure about the former"

would apply so much to today's world. I quit my job in Holland at 64 and retired back to Peru with my wife where we lived the first half of our lives and as a former

motocrosser I never saw an atv as an option. Was I wrong!! They are the perfect go anywhere vehicle,easy to ride,safe ,forgiving and will fit gaps too narrow for a

4 wheel drive. They are though, dangerous for hasty ,and reckless kids (tell me about it)😇.

I wish you lots of happy hours on your 570 and regret not being there to remove the broken grease nipple.

Take care, Buddy

Rob