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Issue 10 Tips and Tricks

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Swingarm Bearing Swap, Leaky Valves, Free Tie Rods, Silicone Just Can't Hang, Lube It Up, Run It Then Clean It, Quick Clip Fix, Locked-Up Clutch, Play It Safe, and the FAQ.

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  • Similar Topics

    • By Frank Angerano
      I would like to hear who uses what to clean there ATV’S. 
      I’ve always been a fan of simple green and it’s always worked well but with this new property and the crazy black mud and clay that’s there  I have to say the simple green is not cutting it. 

      So from cleaning  right after a ride to cleaning them when you find one in a barn I would like to hear what everyone does and what your recommendations. 
      I’m looking to try something new.  
    • By GatorHunter
      Clymer ATV Manual - Polaris ATVs
      You can also find ATV Manuals on Amazon.
      Here is my list, some I have had, some I got online
      I have put all Manuals on my dedicated server, so the links won't go dead. Most the manuals listed below are on the server and there may be some on the server that's not on the list. Scroll to the bottom of this post to get the link.
      If you need a Manual that's not on the list, leave a reply, I will try to locate it, if I can't, I'm sure another member would share if they have it.
      If you have manuals that are not in the list and you would like to share them, leave a reply, with a link to your manuals and I will add them to my post so they are all in one spot.
      Thank you, and enjoy
      GH
      1985 thru 1995 Polaris Service Manual
      Below is the list of machines this Manual covers
      1985 Scrambler
      1985 Trail Boss
      1986 Scrambler
      1986 Trail Boss
      1987 Trail Boss
      1987 Trail Boss 4X4
      1987 Cyclone
      1988 Trail Boss 2X4
      1988 Trail Boss 4X4
      1988 Trail Boss 250 R/ES
      1989 Trail Boss
      1989 Trail Boss 2X4
      1989 Trail Boss 4X4
      1989 Big Boss 4X6
      1990 Trail Blazer
      1990 Trail Boss 250
      1990 Trail Boss 2X4
      1990 Trail Boss 2X4 350L
      1990 Trail Boss 4X4
      1990 Trail Boss 4X4 350L
      1990 Big Boss 4X6
      1991 Trail Blazer
      1991 Trail Boss 250
      1991 Trail Boss 2X4
      1991 Trail Boss 2X4 350L
      1991 Trail Boss 4X4
      1991 Trail Boss 4X4 350L
      1991 Big Boss 4X6
      1991 Big Boss 6X6
      1992 Trail Blazer
      1992 Trail Boss 250
      1992 Trail Boss 2X4
      1992 Trail Boss 2X4 350L
      1992 Trail Boss 4X4
      1992 Trail Boss 4X4 350L
      1992 Big Boss 4X6
      1992 Big Boss 6X6
      1993 250 2X4
      1993 350 2X4
      1993 250 4X4
      1993 350 4X4
      1993 250 6X6
      1993 350 6X6
      1993 Trail Boss
      1993 Trail Blazer
      1993 Sportsman
      1994 300 2X4
      1994 400 2X4
      1994 300 4X4
      1994 400 4X4
      1994 300 6X6
      1994 400 6X6
      1994 Trail Boss 2W
      1994 Trail Blazer 2W
      1994 Sportsman 4X4
      1994 Sport
      1995 300 2X4
      1995 400 2X4
      1995 300 4X4
      1995 400 6X6
      1995 Trail Boss
      1995 Trail Blazer
      1995 Sportsman 4X4
      1995 Sport
      1995 Xplorer 4X4
      1995 Scrambler
      1995 Magnum 2x4
      1995 Madnum 4X4
      1996 thru 1998 Polaris Service Manual
      Below is the list of machines this Manual covers
      1996 Trail Blazer
      1996 Trail Boss
      1996 Xplorer 300
      1996 Xpress 300
      1996 Xplorer 400
      1996 Xpress 400
      1996 Sport
      1996 Scrambler 4X4
      1996 Sportsman 4X4
      1996 Sportsman 500
      1996 400 6X6
      1996 Magnum 2X4
      1996 Magnum 4X4
      1996 Magnum 6X6
      1997 Trail Blazer
      1997 Trail Boss
      1997 Xplorer 300
      1997 Xpress 300
      1997 Xplorer 400
      1997 Xpress 400
      1997 Xplorer 500
      1997 Sport 400
      1997 Scrambler 4X4
      1997 Scrambler 500
      1997 Sportsman 4X4
      1997 Sportsman 500
      1997 400 6X6
      1997 Magnum 2X4
      1997 Magnum 4X4
      1997 Magnum 6X6
      1998 Trail Blazer
      1998 Trail Boss
      1998 Xplorer 300
      1998 Xpress 300
      1998 Sport 400
      1998 Scrambler 400
      1998 Scrambler 500
      1998 Xplorer 400
      1998 Magnum 2X4
      1998 Magnum 4X4
      1998 Sportsman 500
      1998 Big Boss 500 6X6
      1996 thru 2003 Sportsman 400 and 500, Xplorer 500 4X4 Service Manual
      Below is the list of machines this Manual covers
      1996 Sportsman 400
      1996 Sportsman 500
      1996 Xplorer 500 4X4
      1997 Sportsman 400
      1997 Sportsman 500
      1997 Xplorer 500 4X4
      1998 Sportsman 400
      1998 Sportsman 500
      1998 Xplorer 500 4X4
      1999 Sportsman 400
      1999 Sportsman 500
      1999 Xplorer 500 4X4
      2000 Sportsman 400
      2000 Sportsman 500
      2000 Xplorer 500 4X4
      2001 Sportsman 400
      2001 Sportsman 500
      2001 Xplorer 500 4X4
      2002 Sportsman 400
      2002 Sportsman 500
      2002 Xplorer 500 4X4
      2003 Sportsman 400
      2003 Sportsman 500
      2003 Xplorer 500 4X4
      2001 Sportsman 90 Service Manual
      2001 Scrambler 50 and 90 Service Manual
      2001 Sportsman 500 DUSE Parts Manual rev.2
      A01CH50AD
      2001 Sportsman 500 HO Parts Manual rev.3
      A01CH50AA
      A01CH50AB
      A01CH50AE
      A01CH50AK
      2001 Sportsman 500 DUSE HO Parts Manual rev.3
      A01CH50AF
      2001 Sportsman 500 RSE HO Parts Manual rev.3
      A01CH50AJ
      2001 Worker 500 Parts Manual rev.3
      A01CH50EB
      2002 Sportsman 6X6 Parts Manual rev. 1
      A02CL50AA
      2002 Big Boss 6X6 INTL Parts Manual rev.1
      A02CL50DA
      2002 Sportsman 500 HO Parts Manual rev.4
      A02CH50AA
      A02CH50AB
      A02CH50AE
      A02CH50AK
      2002 Sportsman 500 RSE Parts Manual rev.4
      A02CH50AC
      2002 Sportsman 500 DUSE Parts Manual rev.4
      A02CH50AD
      2002 Sportsman X Parts Manual rev.4
      A02CH50AJ
      2002 Sportsman 500 HO Freedom Parts Manual rev.4
      A02CH50AL
      2002 Sportsman 500 PSE HO Parts Manual rev.4
      A02CH50AM
      2002 Sportsman 500 Parts Manual rev.4
      A02CH50AN
      2002 Desert Sportsman 500 Parts Manual rev.4
      A02CH50FA
      2002 Worker 500 Parts Manual rev.4
      A02CH50AAEB
      2002 Sportsman 700 Parts Manual rev.2
      A02CH68AA
      A02CH68AB
      A02CH68AC
      A02CH68CA
      A02CH68CB
      2002 Sportsman 700 Service Manual
      2003 Sportsman 6X6 Owners Manual
      2003 Sportsman 6X6 Parts Manual rev.1
      A03CL50AA
      2003 Sportsman 6X6 Service Manual
      2003 Sportsman 400 and 500 HO Service Manual
      2003 Sportsman 400 Parts Manual
      A03CH42AA
      A03CH42AB
      A03CH42AC
      2003 Sportsman 500 HO Parts Manual
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      2003 Sportsman 600 and 700 Owners Manual
      2003 Sportsman 600 and 700 Service Manual
      2003 Sportsman 700 Parts Manual rev.4
      2003 Predator Parts Manual rev. 1
      A03GJ50AA
      A03GJ50AB
      2003 Trail Boss 330 Service Manual
      2004 Sportsman 6X6 Parts Manual
      A04CL50AA
      2004 Sportsman 6X6 Owners Manual
      2004 Sportsman 6X6 Service Manual
      2004 Sportsman 400,500,600 and 700 Owners manual
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AA
      A04CH42AE
      A04CH42AG
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AQ
      A04CH42AT
      A04CH42AV
      A04CH42AS
      A04CH42AR
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AA
      A04CH50AC
      A04CH50AE
      A04CH50AG
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AO
      A04CH50AQ
      A04CH50AR
      A04CH50AS
      A04CH50AT
      A04CH50AV
      A04CH50AW
      2004 Sportsman 600 Parts Manual rev.2
      A04CH59AF
      A04CH59AH
      A04CH59AJ
      A04CH59AT
      A04CH59AV
      2004 Sportsman 600 Parts Manual rev.1
      A04CH59AK
      A04CH59AL
      A04CH59AN
      A04CH59AW
      2004 Sportsman 600 and 700 Service Manual
      2004 Sportsman 700 Parts Manual rev.2
      A04CH68AC
      A04CH68AF
      A04CH68AH
      A04CH68AJ
      A04CH68AT
      A04CH68AV
      2004 Sportsman 700 Parts Manual
      A04CH68AK
      A04CH68AL
      A04CH68AN
      A04CH68AO
      2004 Sportsman 700 MV Parts Manual
      A04CH68MB
      2004 Sportsman 700 MV Service Manual
      2004 Ranger 2X4 Parts Manual
      A04RB42AA
      2004 Ranger 4X4 Parts Manual
      A04RD50AA
      2004 Ranger 6X6 Parts Manual
      A04RF50AA
      2005 Sportsman 6X6 Parts Manual
      A05CL50AA
      2005 Sportsman 6X6 Owners Manual
      2005 Sportsman 6X6 Service Manual
      2005 Sportsman 400,500.600 and 700 Owners Manual
      2005 Sportsman 400 Parts Manual
      A05MH42AB
      A05MH42AG
      A05MH42AH
      2005 Sportsman 400 and 500 Service Manual
      2005 Sportsman 500 HO/INT'L Parts Manual
      A05MH50AB
      A05MH50AC
      A05MH50AG
      A05MH50AH
      A05MH50FB
      2005 Sportsman 600 Parts Manual
      A05MH59AK
      A05MH59AN
      2005 Sportsman 700 Parts Manual
      A05MH68AK
      A05MH68AN
      2005 Sportsman 700 EFI Parts Manual
      A05MH68AC
      A05MH68AS
      A05MH68AU
      A05MH68AW
      2005 Sportsman 700 EFI and 800 EFI Service Manaul
      2005 Sportsman 800 EFI Parts Manual
      A05MH76AC
      A05MH76AU
      A05MH76AW
      2005 Sportsman MV7 Parts Manaul
      A05MH68AP
      2005 Sportsman MV7 Service Manual
      2006 Outlaw 500 Service Manual
      2007 Sportsman 6X6 Service Manual
      2007 Sportsman 450 Service Manual
      2007 Sportsman 500 EFI Service Manual
      2007 Sportsman 500 X2 EFI Service Manual
      2007 Sportsman 700 Service Manual
      2007 Sportsman 800 Service Manual
      2007 Sportsman 800 EFI Service Manual
      2007 Sportsman 700 MV Parts Manual
      A07MH68MA
      2007 Sportsman 700 MV Service Manual
      2007 Outlaw 500 Service Manual
      2007 Ranger 700 EFI 6X6 Parts Manual
      R07RF68AD
      R07RF68AF
      2007 Ranger XP 4X4 Service Manual
      2007 Ranger XP 6X6 Service Manual
      2008 Sportsman 500 Service Manual
      2008 Sportsman 500 EFI Service Manual
      2008 Sportsman X2 500 EFI Service Manual
      2008 Sportsman Touring 500 EFI Service Manual
      2008 Sportsman X2 700 Service Manual
      2008 Sportsman 800 EFI Service Manual
      2008 Sportsman 800 Touring Service Manual
      2008 Ranger 6X6 700 EFI Parts Manual
      R08RF68AD
      R08RF68AF
      2009 Sportsman 6X6 800 EFI Service Manual
      2009 Sportsman 90 Service Manual
      2009 Sportsman 300 Service Manual
      2009 Sportsman 400 HO Service Manual
      2009 Sportsman 500 HO Service Manual
      2009 Sportsman 500 EFI Service Manual
      2009 Sportsman X2 500 EFI Service Manual
      2009 Sportsman Touring 500 EFI Service Manual
      2009 Sportsman 800 EFI Service Manual
      2009 Sportsman X2 800 EFI Service Manual
      2009 Sportsman Touring 800 EFI Service Manual
      2009 Sportsman XP 550 Service Manual
      2009 Sportsman XP 550 EPS Service Manual
      2009 Sportsman XP 850 Service Manual
      2009 Sportsman XP 850 EPS Service Manual
      2009 Outlaw 90 Service Manual
      2009 Outlaw 450 MXR Service Manual
      2009 Outlaw 525 S Service Manual
      2009 Outlaw 525 IRS Service Manual
      2009 Predator 50 Service Manual
      2009 Ranger RZR Service Manual
      2009 Ranger RZR S Service Manual
      2009 Ranger INT'L Service Manual
      2009 Ranger 2x4 Service Manual
      2009 Ranger 4x4 Crew Service Manual
      2009 Ranger 6x6 Service Manual
      2009 Ranger 500 4x4 EFI Service Manual
      2009 Ranger RZR 170 Service Manual
      2009 Ranger XP 700 4x4 Service Manual
      2009 Ranger HD 700 4x4 Service Manual
      2009 Scrambler 500 Service Manual
      2009 Trail Blazer 330 Service Manual
      2009 Trail Boss 330 Service Manual
      2010 Ranger RZR Service Manual
      2010 Ranger RZR S Service Manual
      2010 Ranger INT'L Service Manual
      2011 Ranger RZR SW Service Manual
      2011 Ranger RZR Service Manual
      2011 Ranger RZR S Service Manual
      2011 Ranger RZR 4 Service Manual
      Other Stuff
      2500lb Polaris Winch Install Instructions and Parts List
      2500lb Warn Winch Install Instructions
      2500lb Warn Winch Parts Manual
      Warn Winch Motor Rotation Instructions
      Warn - The Basic Guide to Winching Techniques
      Sportsman 600 and 700 Ignition Replacement Kit Install Instructions
      Polaris Special Tools - ATV,Snowmobile,Watercraft
      Download Manuals HERE
    • By MarkinAR
      Passing thought here and thought I'd pitch it to the group for debate.  I'm working through a Kodiak which is basically a Big Bear in a heavier bike and the same as about anything Japanese made for 30 years as far as clutch function and design goes.  This Kodiak is odd though in that the centrifugal clutch slipped a bit with good clutch material remaining and the main clutch pack seems to slip a bit as well at high RPM but also still has good clutch material left.  Much like the Kawa race bikes from what I've read.  Do you think it's an option to add a thin washer to the pressure bolts to put a bit more pressure on the main clutch and force it to use a bit more of the clutch material before having to replace?  There's seriously like 50% of fiber left on the main clutch pack and it seems silly to replace it all before it's truly worn down.
    • By MarkinAR
      About done with the Kodiak finally. Oldest took it out today and ran the piss out of it, buried it to the belly, and I think its finally about ready to trust. However, there is a clutch slipping that needs to be addressed. It pulls fine from a dead stop to about half throttle. If you go ahead and open it up, the clutch basically lets go at higher RPM. My question then is; centrifugal clutch or main clutch pack bad? I assume since it pulls at low RPM then it's the main clutch pack slipping at WOT. School me though: where does the centrifugal clutch end and main clutch pack begin?  Also added to this issue, he was crusing down a gravel road and all 4 wheels locked up and it died. I assume it tried to throw 2 gears at the same time and locked up. It unlocked though and shifted ok after coming to a stop. 
    • By Monika Novakov
      1988 Kawasaki 220 Bayou trying to remove generator/ starter 1way clutch cover to be able to replace 1way clutch. All bolts are removed case cover is dripping what oil that remains...but I can't get the cover to come off..what am I missing? Thx in advance.
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      Hi everyone, I received a 98 Yamaha Timberwolf from my brother for free, and I'm working on getting it going. 
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      Hi,
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