flyinbrian365

I recently rebuilt a customers Polaris Sportsman 550 transmission, re-shimmed the synchronizer, and shimmed the primary drive clutch for much easier shifting as these are very difficult to get into gear or shift from one gear to another. The video is after shimming the drive clutch for more belt clearance.

 

 

  

The files it too large to upload so here's a link to my dropbox.

https://www.dropbox.com/s/boeo3kewqeuj7td/2016-20 SXS Pioneer 1000M3-M3P-M3LE-M5P-M5D-M5LE service manual.pdf?dl=0

https://www.dropbox.com/s/z6kjj2to6yyneip/2015 SXS 500M2 Pionneer service manual.pdf?dl=0

 

Hope this helps someone!!

 

Yeah a CDI off a different machine could have a different timing degrees than yours and that's why your having the kickback issues. 

For example that CDI might be set a 6* before top dead center to fire and your OEM CDI might be set at 4* BTDC

Yeah the CDI controls the ignition timing and advance, is the CDI unit your testing for that machine? 

If not that could be your kickback and starting issues.

 

Looks like there are 2 different manuals in the ATV file.

 

Just uploaded the full service manual.

 

 

I just worked on one of these machines for a customer of mine. I completely rebuilt the carb, sometimes at idle it would load up like it was running too rich. The another issue he was having was it would suddenly stall when you came to an idle then start right back up. Both of these problems are caused by a bad fuel valve, the vacuum diaphragm gets deteriorated and starts pulling fuel through the vacuum hose or doesn't flow fuel correctly. I've had 2 customers with 2 different Suzuki model ATV's with the same issues a bad fuel valve assembly. There are no rebuild kits and the oem valves are much higher quality than after markets so just spend the money and put a good one on it.   

 

 

 

 

Looks like it's pending approval from the admin.

it's located under the ATV repair manuals tab

just added the 2002 Magnum 325 /500 service manual

 

There is one on the ATV repair page. 

1985-95 Vol. I ATV and Light Utility Hauler service manual

Yes I believe they are the same up through 2020.