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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 Dra O
posted a while back - it was running at one point - I have all the plastic shroud off - it's down to frame and engine now
-fuel pump: when line from petcock is attached, no fuel comes out other side to carb; the line to the carb is open (can blow through it); I thought when I cranked engine that the pump would spit out fuel on other side but it does not; I removed fuel pump and opened it up - diaphragm looks good - but internal areas had lotsa calcification build up - I cleaned this out and dried it good - the clear plastic pieces (?diaphragms) aren't broken - the spring w/ steel ball on end moves freely; am putting it back on tomorrow; but can anyone answer about the pump? isn't it supposed to pump fuel through it... to other side... to carb? puzzling
-along with fuel pump: I replaced petcock 3 weeks ago (gas tank had rusty fuel in bottom - cleaned it out prior to new petcock); when I turn petcock arrow NOT to on or reserve, fuel comes out of line; when I turn it to on or reserve, fuel doesn't come out; puzzling
-I don't know what's on back of fuel pump - it's a valve that has a hose coming out of it - looks like it goes to engine/carb - I haven't traced this out yet - what is it?
-can squirt gas on air filter and engine will run for 2-3 seconds then stop - fuel in top of carb (under diaphragm) does same
-it likely needs carb rebuild - will get to this - but something isn't allowing fuel to get from fuel pump to carb
-I THINK it has a mikuni model x carb - diaphragm is ID 26mm OD 68mm - hard to find inexpensive diaphragm, I guess because it's a model x
-last thing - I replaced solenoid due to old one clicking; I HAVE to be charging the battery or it won't start/turn over - battery just goes dead; but if charging, it'll turn over nicely; i'm guessing it's a bad battery
-any help appreciated - I've never owned an ATV before - inherited this beast from grandparent in-law
Just got a new to me, 99 Kodiak w/ plow and an extra set of tires for dirt cheap. I'm curious where you guys purchase your parts for your older ATV's? Google is great to find parts, but I'm hoping you guys have some stores, online, that you prefer on a recommendation basis. I've already purchased my tune-up items, but the brakes need some work and I'll likely end up having to replace the steering stem bearing, front CV axles and a few other things down the road.
So honed out the cylinder and got most of it nice nice but left with this .. Might just have to have the things bored out now ..... some before and after..pics.
1995 Polaris Sportsman 400 4x4
have to have the things bored out now ..... some before and after..pics..
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I have an 04 ltz and it started sputtering a little bit while going down the road and I was low on gas so I just figured that's what it was. But now I can't get it to start I completely cleaned the carberator put a new spark plug and coil pack in it and all it does is turn over. It has compression it's getting fuel and it is sparking but all it does is turn over any idea what it is??
Just signed up, as I've had a recurring problem, and need some help.
To start the bike I have to put the choke on all the way and 4 squeezes on the gas, Then as I push the start, I slow squeeze the throttle about half way for it to catch....If I miss it, then it will take 5 mins of slowly finding the sweetspot on the choke in unison with some throttle squeezes.
Then I have to to hold the throttle to keep the bike going, using the choke will stall it out. after about 3 mins of holding the throttle, I then can let it go, and it idles fine, and runs fine. If it sits for a few hours it's only slightly hard to start, but a few days of sitting, and it's a lot more work.
Had the bike serviced they couldn't figure it out. They swapped peticock, plug, new gas, all new lines, new throttle, and cable. Said the carb was fine, and clean. New air filter, said fuel pump was fine, no leaks around carb boots, new battery, new rectifier.
Ran some sea foam through it....Runs Great.....Just such a pain to start...
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