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having an issue with the unit when running under a load up a hill or in high gear, seems like the belt is slipping, there is a clapping sound coming from the primary clutch like it releases and snaps back in. i don't think I should have a noise like that. this is a friends unit and he has already replaced the primary twice with the same result. not sure where to look next

Anyone have a problem with the Polaris instrument cluster/speedometer frozen(part # 3280453) ? Mine is always showing R and slow now(see photo), Did it go bad or can you reset it or is something else the problem. It is on a 2004 Sportsman 500

Does anyone have a manual they could post for the 2004 ( or similar year) Sportsman 500. Manu Thanks

Hey, I have had this quad since new. The oil change is a pain in as* cause I have to remove the plastics, foot well, etc to be able to get to the drain plug. Any one have an easier way? Thanks Cash

Do you recommend flushing and changing out the transmission oil in the 1996 Polaris Sportsman 500 I am trying to put back on the road? Not leaking and looks clean.

I am renovating a 1996 Polaris Sportsman 500. The owner lost the key, so I bought an aftermarket ignition switch. I noticed that this new key actually seemed to work in the old switch. Do you recommend replacing it or using the old switch?

I am renovating a 1996 Polaris Sportsman 500. It has not run for several years and stood outside in the owner's yard. There was some gas left in it which I need to drain. Do I need to drain the tank, fuel pump, and carburetor? Is there one place to drain it all?

With this old (1999) Polaris Sportsman 500 which has not run for several years, do you recommend flushing and changing out the coolant? It is not leaking and looks good.

View File 1997 Polaris Sportsman 500 Service Manual 1997 Polaris Sportsman 500 Service Manual Submitter Admin Submitted 05/23/2022 Category Polaris ATV  

Hi all, I have a 2003 sportsman 500 ho that I purchased a CDI for to replace the previous one however it was modified by someone else to use a different one I have all the correct wiring however I have to make the correct pigtail will anyone be willing to share a pic of how theirs is setup any help would be appreciated as I have been working on this bike for 2 months

I've already posted here once about this ATV. Lots of people suggested i check the cam and after a couple months i finally got around to attacking it. I got it all apart and got the cam/rockers out. I'm almost positive they need to be replaced, they're pretty scored up and don't look too hot. Just wanted some final opinions before i drop the money on it. I'll also take feedback on the new cam i've chosen. Old Cam: New Cam: https://www.amazon.com/hz/wishlist/ls/2GM2J05FQQPCD?ref_=wl_share Old Forum: Thank You.

Hey there, i have recently put a new drive belt on my 11 Polaris Sportsman 500 H.O. It has 44 miles since putting the new belt on and should be nearly broken in as i hear it takes 50 miles to do so? Anyhow it has had a little trouble with slipping since i put the new one on a few months ago. Now whenver i go down a hill the belt seems to be getting caught in one clutch if not both and then it has to run a high rpm just to go a low speed. Today it did that again going down hill, i stopped, put it in neutral and when going back up the hill i had to turn it off, put it in neutral, let it roll back down the hill a little, then restart it, low range and it was slipping but thankfully i was able to make it up the hill. So what might the problem be? Is this a need for another new belt? New clutches and belt? Or just get something else? BTW the brand new belt i put on it, is a factory one, an exact replacement for the original.

Hi All! So, I have this ATV. it ran perfectly fine all up until we took it out after a snow to play. then is started stalling only when i would accelerate. It will run at idle all day long. Any ideas on what to do. I also tried to see if it was going to throw a code and it produced nothing. However, it will occasionally throw the wrench symbol every once in a while. Any help would be appreciated.

500 HO. I have yellow, orange and violet wire colors. One of the wires broke off. I rigged it to work and the Check indicator went off. Took it to a dealer for a low power problem and they kindly tore off a second wire and the one I repaired. Now I don't know which is which in the plug. I got a replacement plug from OTC and it has red, black and yellow. I just need someone to look at theirs and tell me the color order. The yellow is on the right. Thanks

Ok so 2000 sportsman new.caltric carb new fuel pump new jug and piston new cdi and coil finally get to start it and itll idep for 5 to 10 seconds and die what am i missing people any help id love ya forever lol Sent from my LM-Q720 using Tapatalk

Can't figure out whats wrong, battery good, charging fine but speedometer needle flashing. I know my fuel sending unit is not working but atv was working well last year. Now it was blowing fuses. I did engine code check but none there. Gas gauge flashes and shows FUEL in capital letters. Need help as just cannot figure this out, I might pull the fuel pump out and put new float as likely saturated. Don't know if that would give me all these problems ?? thanks

Have a 2001 polaris sportsman 500 4x4 atv and when I put coolant in the radiator it starts leaking from the exhaust. The valves are sealed but it stopped making compression. Do I need to just replace the head? I just rebuilt the hole top end and this is the only thing +valves that I have not replaced and was wondering if that is why it's not starting up. Need answers please.

Has anyone had any luck putting a different gauge on this machine. Would you happen to have the wiring diagram?

Hello bought my 2000 polaris sportsman 500 last week bike seems to work pretty good untill yesterday, when in reverse the bike seems to start bogging out? How come?

Well its finally happened, its time to replace the belt on my 2011 Polaris Sportsman 500 H.O. Is there anything specific i need to know before getting into it? Is there one brand of belt i should get over another? I'm still on my first Polaris and plan to keep it at least another 8 years.

I have a 2000 Polaris Sportsman 500. The Speedometer got water inside of it and it sat for a long time. So now that speedometer is trashed to say the least and i need to find a replacement. I don't want to put up the cash for an oem one so i was wondering if anyone knew any good speedometers out there i could use. I've found many speedometers i like but don't know how i'd wire it up without the same connection points. Thanks, any input is appreciated

Just bought this ATV. Wondering if my gauge from a 2003 will plug in and work. I know mine does not have a fuel gauge, but if the rest works, I am in.