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Found 390 results

  1. My 2004 polaris scrambler 500 started to backfire ,then i was able ti limp it into the driveway and it died . I tried to start it but when i turned the key there was no power to the rest of the quad . my winch still worked but its wired straight to the battery . I had noticed a sound coming from the sylenoid by the battery during previous times i started the engine but then i would turn off the head light and it would start fine . I replaced that but still no dice with the rest of the system . Anyone else ever had this problem ???
  2. When my grandkids Polaris 90 wheeler gets hot it is hard to start...its been this way since new. Were these subject to vapor lock ? Thanks
  3. I am desperately seeking some help from all of you on trying to locate a free download of a manual. One of the biggest problems that I have is that I'm very computer illiterate. So if anybody can help me, by sending me a link to a free download on the manual that I am requesting. It would be much appreciated. Or if you can email it to me that would be the easiest for me. [email protected] Thank you for your time, hope there's somebody out there that can help me.
  4. I was pushing snow this morning and all of a sudden my Polais just died (Everything died on it) I changed the battery and checked the fuses which are all good. Any suggestions will be greatly appreciated. Happy New Year
  5. Hi Everybody My questions to forum members – Has anybody ever been told they need extra maintenance on their ATV at all, other than what is specified in the maintenance manual, anywhere in the world? Is it just my bikes having this issue? It is a progressive starting problem until they just don’t start at all. Can they be fixed? Why Do I ask? My name is Kim and I was running quad bike and gold prospecting tours in Western Australia until recently. I have lost too much money investing in the bikes. I had purchased 6 Polaris Quad Bikes from Polaris Central in Perth and received them in June 2012. This cost over $60,000 AU. The bikes were never abused and maintenance was performed to specifications. 5 out of 6 six bikes had some serious issues. As two of the bikes are completely broken down within hours after being sent back to Polaris to be fixed, I pursued Polaris to get answers to the constant problems and wanted to have the bikes fixed properly. Polaris Australia response was the following: We are aware of the very fine dust that is in the northern parts of Australia. In these extreme dust conditions additional air filter maintenance is required on any internal combustion engine. If the air filter becomes plugged with dust, the vacuum of the engine will suck in dust from an alternative location, we believe this is what has been happening with your units. We repaired 2 of your units as good will as we are certain that this issue was not caused by a defect, rather through a lack of air filter maintenance. Unfortunately this has caused the engines on your units to ingest dust which has resulted in engine damage and excessive oil consumption. Regrettably Polaris will not be able to repair these additional engines under warranty. Firstly we are not in Northern Australia Secondly we were not informed by word of mouth or in writing that the bikes needed “EXTRA” filter maintenance Thirdly, I am curious to know why they are selling the bikes in Australia if they cannot handle the Australian Conditions Lastly, the two bikes they supposedly repaired under “GOODWILL” broke down totally within hours of use. Any help would be great thanks Kim
  6. I jus got a 04 polaris scambler. The guy ensured the 4x4 works but he had the chain slid off and zip tied to the frame for the 4x4. Well i took the chain off cause it looks rough and was in the way. However before i replace the 4x4 chain, i engauged the 4x4 to see if the sprocket would even turn. And it did. The problem is i hit the 4x4 awd button again to turn it off and the sprocket is still turning for the awd, is there a specific way to disengauge the awd 4x4? Also the main drive chain and the other chain are rather loose, they are just tight enough for it not to come off, is this average? Should it be tighter it seems or do they run them like that. Another thing i have a problem w is the read brakes, aka right foot brake. The guy took the caliper off and everything is has no rear brakes. I need to buy all of that, what exactly all do i need, theres jus a rotor there. And any diagram for installation?
  7. I need some help from you guys to figure out which quad I should buy. I am torn between the 2015 Polaris Sportsman 570 and 2015 Honda Rancher 420 (4x4, electronic shift). They are roughly the same price and seem to have similar features, dont care about power steering on either. Obviously at first glance the Polaris seems better because it is quite a bit more CC for same price. All else equal, what do you think is a better machine? I have always thought of Honda as being superior and "going forever" but I have also heard Polaris has come "a long way" (according to the Polaris sales guy the military uses Polaris). I just do not want to regret in 8 years from now not going Honda.. but am admittedly leaning Polaris. Thanks! Cal.
  8. The "engine hot" warning keeps flashing even when the bike is off for several hours. i unplugged the temp sensor and had it tested. It appears to be fine. With this warning flashing the fan wants to run all the time. I have not been able to locate a wiring diagram on the net, is there a relay that could be stuck?
  9. If you have been affected by clutch/shifting problems with the 2011-2014 Polaris Ranger Diesels, or any other Polaris UTV's or ATV's, please see the following thread: Ranger Diesel Nightmare - RangerForums.net - Polaris Ranger Forum You are far from alone. There are hundreds if not thousands of other people who are affected by this same issue. The only half-proven solution is to buy an aftermarket clutch for $1500 from a separate company, which is conveniently founded by an ex-Polaris engineer. In addition, the sticking clutch eventually leads to catastrophic transmission damage. I paid $12,000 for a Diesel Ranger in 2011, and it has been difficult if not impossible to shift for the majority of its life due to a factory-defective clutch. The sticking clutch wears out the transmission, and eventually you will be faced with a $2500 bill to have it replaced. If you or anyone you know has been affected by this clutch, please visit the thread linked above and make your voice heard.
  10. I had some leaky seals and a bad running Polaris 250 2x4 mod W937527.Compression was 90 lbs.Just had the cylinder to a shop for measuring.Standard 72mm is 2.835 inches this cylinder is round and measures 2.839 and a bit wider at the bottom.The ring gap with the used rings is .25. Here is my question>The piston has the ring stops that pin,Can I use the standard piston with a ring set .10 over? The manual says ring gap seated in the cylinder should be .0009 to .0018. I am disabled and it will only run me 800 ft to a mailbox once a day and maybe a little use around the yard,so a bore,and new parts are out fixed income cant afford that. Can I go .010 over on the rings with the standard piston? Thanks for any advice
  11. Hi guys, I have a Polaris Sportsman 500 1997 model, Going back last year the head blew so i replaced the head which i don't think has anything to do with the problem i am having now but now whenever i take it out for the first 10 minutes it goes good but after that once it gets warm it seems to lose power and cut out quite alot and sounds a bit louder than normal, When it starts cutting out you hit the throttle and it just doesn't react then all of a sudden it will and just keeps happening more often and conks out. Any ideas on what could be wrong with it? When the bike is cold it seems to run good. Appreciate any help.
  12. Im working on a polaris trail boss 350 and need the secondary off can i use a bolt and if i can what size is it?
  13. hi guys, I just got a 1999-2000 Polaris sportsman 500 4x4. it idles good but when you give it gas it bogs and stalls out! have checked the carb and readjusted it and its still stalling! checked the fuel lines and pump all good, checked spark plug and wires all good. anyone know anything about this bike pleas let me know!
  14. hi guys, got a new bike yesterday a Polaris sportsman 500 4x4, it has a 4in lift and new mud tires, nice new rims to, I traded my old work truck for it. the bike is nice! the guy that had it had the carb rebuilt and now it will idle but when you give it gas it stalls out? I took the carb off and checked it, everything looked good. but it was still stalling so I rechecked the carb, even checked the air box the sparkplug the fuel the fuel lines but its still stalling! anyone know anything about this Polaris I can use the help! im at a loss as to whats wrong with it!
  15. will the xplorer 250 2000 model rear axle fit in a 2000 trailboss 325
  16. Can someone help me diagnose a wheel wobble? My left rear wheel wobbles. It does it on 2 different set of tires so I can say it is not the rim and I replaced the hub so its not that. What are my next steps in figuring it out or does someone already know Thanks in advance for any and all help Regina
  17. Polaris Ranger Utility Vehicle Owners Earn $200 (Atlanta) DO YOU OWN A POLARIS RANGER 500 OR 570? EARN $200 We are a market research company that pays people for their time and opinions. We are not selling anything; we are only interested in your opinion which will help the manufacturers develop better products in the future. We are going to be conducting a Utility Vehicle focus group research study in Atlanta on Wednesday and Thursday June 11th. & 12th. at 6:00 PM. You will have an opportunity to share your opinion regarding current and future utility vehicle designs and will be paid $200.00 for your time. If you don't own one of these utility vehicles, please tell your friends about this study. WE ARE LOOKING FOR MODEL YEARS 2010 OR NEWER. REGISTRATION OR BILL OF SALE IS REQUIRED AS PROOF OF OWNERSHIP. Please call A Point of View Research ASAP to see if you qualify and register for one of the days. Thanks Pat 714-891-1888
  18. hey guys my name is preston and i just joinned the fourm and so far i am glad i did so. that aside me and my frien jus aquired a 1985 polaris trail boss with a blown motor for $50 and we have a crazy plan for it. we wanna take the existing frame ans strip it down to a rolling frame and then turn it into a go kart. Now the reason that we wish to do so is because we think its a moderatly easy way to build a Kart with both front and rear suspension. i am wondering if anybody has tried this with similar quads or any input in general would be great.
  19. i have a 2003 polaris trail boss, it hasent been run i about 2 years. the shifter is froze up and wont budge, does anyone know how to get it unstuck? also i need to know what wire to unplug so i can get it too start in any gear. thanks
  20. I bought a 2000 polaris scrambler,that will not start ,I had the carb rebuilt bought a new battery and clean :confused:the air filter system and bought a new spark plug and installed everything properly and the bike still will not start I have placed an extra hot wire on the spark plug to the sparkplug wire and it is getting low spark because it shock me ,So now I have bought a new ignition coil that I need to install I am not sure if that is going to get the little engine to fire anybody got any other ideas ?
  21. I have a 2000 Polaris Scrambler 50 with a new starter and new battery. The battery and starter are strong but when engaging the starter it wont start. But it will start with a manual crank. There are 3 unconnected wires under the cover, but I dont know where they go. Am I missing a part that might be preventing the starter from starting it? Maybe some safety switch or something? Does anyone have a manual for this model for download? Thanks in advance for any help!
  22. i have a 2001 Polaris 500 ho has not been started in about two years before then i was a pain to start basically had to jump it off with a car battery after it ran for a little bit it was fine just had to pull start it a the rest of the day i believed i smoked the belt while riding it one day and started it a couple of times after that but its been sitting for a while any body know where i should start about getting it back up and going.
  23. New to this site here, but wanted to get some opinions on the Polaris 400 HO. Seriously thinking about getting one. Grew up riding motorcycles, a Honda 250 3 wheeler and a 4 wheeler.
  24. I have a 2007 Polaris Outlaw 525 KTM. The rear wheels locked up while riding. I read where it could be a retention bolt or retainer plate. Could anyone tell me where they are located and how difficult it is to fix. Thanks
  25. This is a 2008 Polaris Sportsman 500 X2 modification to make the taillights only come on when the headlights are on. Normally the taillights are always on, which I admit is very helpful when following someone on the trail in lowlight conditions. I prefer to have the option of when the lights are on, so I installed the following mod to my Polaris. Parts: - 1 x Bosch style relay. Amazon: AGT (5 Pack) 30/40 AMP Relay with Harness; spdt 12V Bosch Style (40AMP-HRNS) for 13.99. - 1 x 1N400X diode (I used a 1N4004, but any diode in the series should be fine) - Wire connectors, preferably marine grade heat shrinkable. - Heat shrink wrap. - Wire protection: split loom and nylon sleeve. - Wire: 5 feet of 16-18 gauge. Bosch relay info: CHETS CIRCUITS (and scroll down to yellow diagram near mid page--thanks Chet) Basic concept: 1. Splice into a headlamp wire and run it to relay pin 85; ground pin 86 to the frame. 2. Cut the two taillight wires (L and R), and connect one side of the cut (both L and R) to relay pin 30, and the other side to pin 87. 3. When the headlights are on, power from the headlight wire to pin 85 causes the relay to close the taillight connection through pins 30 and 87 to make the taillights turn on. When the headlights are off, the connection between pins 30 and 87 is open, resulting in the taillights being off. 4. The brake lights are on their own circuit, so will still work normally. 5. The relay only draws about 170 milliamps from the headlight splice so there is no apparent change in headlight intensity. 6. I don’t think joining the individual L and R taillight wires to pass through the relay (pins 30 and 87) has any effect on the electrical system since they come from the same splice upstream. My install used a 5 pin relay with pig tail wire connector. I removed the unneeded center pin wire (87a pin): [ATTACH]1759[/ATTACH] I pulled out the 85 and 86 wire pins and soldered a 1N4004 diode in as a precaution against back EMF. Back EMF is a voltage spike caused when power is removed from the relay that could cause damage to switches in a system not specifically designed to have a relay. An electrician may know better whether or not this is needed to protect the headlight system of the quad. Note the diode’s cathode end must connect to the power wire (pin 85 in this case), and anode end must connect to the grounded wire (pin 86), I.E. Reversing the diode polarity will cause a short and potential damage. An option is to purchase a relay with an integrated diode. Diodes are cheap at Radio Shack. I suspect installing a diode is overkill, but I had the time and energy . . . Soldered in diode and with connectors and diode reinstalled: [ATTACH]1764[/ATTACH] Next, I found a place to mount the relay. On the left side frame, next to the air box, was a foot-well brace bar that bolts into the frame. I mounted the relay on this bolt and also connected the relay ground wire (pin 86) to the bolt by crimping a ring connector to the wire: [ATTACH]1762[/ATTACH] Then I very carefully removed a half inch of insulation from the front left headlight power wire (a green wire on my quad) and soldered in a wire to connect to pin 85. I put a nylon sleeve on this wire and ran it back to the relay, following existing wire looms and zip tying it in place: [ATTACH]1763[/ATTACH] Next I accessed the taillight wires--the PS500 X2 made this easy since it has a dump bed that lifts up. For typical quads, you may need to remove the rear storage rack to access the taillight loom. As you can see in the pic, my taillight wires are red w/white trace, the brake light wires are orange, and the ground wires are dark brown. Cut the taillight wires and crimp on connectors, then connect to pins 30 and 87 (black and blue wires in my case). Polarity doesn’t matter. View from above: [ATTACH]1763[/ATTACH] Made all the connections to the relay then tested the light system. Worked like a champ. I used shrink wrap and tape to seal the connections then put split loom wire protection over the wires between the relay and taillight loom and zip tied everything in place. I also spliced in a license plate light to the taillight circuit. I used tape to mask the dome so only a slit is open to shine softly on the plate. Had a couple more pics, but apparently can only upload up to 5 total, or per post.

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