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View File 2005 Polaris Predator 50/90 Sportsman 90 Service Manual This is the factory service manual for the 2005 predator 50cc and 90cc, Sportsman 90cc. Download all the chapters for the complete manual or just the sections you need. Submitter colin james Submitted 04/06/2019 Category Polaris ATV  

TPS on Polaris SPORTSMAN 500 efi 2007 shows as bad original part number is 3140173 bought the replacement part it came in as 3131705 the diameter of the ring on the face is 26 mm the original is 18 mm any thoughts on how this "factory" replacement parts fits as i cannot get it to go in?

I have a 2017 Sportsman 570 SP with a power steering issue. Dealer tells me my machine is one that is not covered by recall and offers no help other than bring it in they will look at it. Any ideas?

Hi, I am having the hardest time figuring out where and how to line up the flywheel for TDC on my sons 2019 Sportsman. The older models where much easier and the identification marks are self explanatory but this ones different and I can’t find a service manual. Any help would be awesome?

View File 1996-2003 Polaris Sportsman 500 Service Manual 1996-2003 Polaris Sportsman 500 Service Manual Submitter Ajmboy Submitted 06/26/2019 Category Polaris ATV  

Does anybody know how to determine which of the 2 key blanks fits my ATV. I have called several dealers, and Polaris and nobody seems to know which key fits which ATV. I thought with the ViN number they could look it up, but apparently not. I hate to spend the money at Polaris for a key blank and then pay a locksmith to cut it, but the locksmiths around me don't have the Polaris keys in stock. I find them on Amazon and places, but I can't tell which key blank is right for my ATV. Any help would be appreciated.

I have a 1999 Sportsman 500, it was running fine, than started to lose power in the winter, I adjusted the idle screw and away I went, than a few weeks ago it died, I have found that i am flooding the engine, compression was at 70PSI and due to the compression release mech. i assume i am good as it compared to the same PSI on a 2000 sportsman 500 i have. i cannot start the atv unless i go full throttle and it starts an runs for about 30 sec than dies, again it is flooded. i ordered a new carb off ebay as i could get one for around $40. put that in same issue, i have checked the timing, (good), valves out of adjustment i adjusted to .006 still same issue, i have found the exhaust lobe and rocker arm to have some wear, i have ordered new ones, but am looking for any other input in this area as well. would the exhaust cam and rocker arm cause the engine to flood? i have used a bore scope and the piston liner has good cross hatching still? any input would be great.

Something I've noticed with the AWD on/off operation. When AWD switch is in the on position and the AWD light is on (trans engaged), turning the AWD switch off kills the engine. With trans in neutral, AWD light is off, turning switch off does not kill engine. Since I don't have the operators manual yet, I'm wondering if this is normal operation? Thanks, Ray

View File 2014 Polaris Sportsman 570 EFI EPS Owners Manual 2014 Polaris Sportsman 570 EFI and Sportsman 570 EPS Owner's Manual for Maintenance and Safety Submitter Georgeann Stricklin Submitted 06/10/2019 Category Polaris ATV  

Problem: The ATV starts and runs at idle perfectly. But as soon as I open the throttle, the engine starts to slow down until it stops. On the attached video you can hear the sound of how it works: see video below Prehistory: there is a Polaris Sportsman 500 1998, which for about 1.5 years stood in repair, including also replacing CDI with one taken from the same ATV. Finally, the vehicles were on wheels, traveled several kilometers and overheated - forgot to fill the antifreeze Came back home in small moves. The next trip started well, but after 10 km there was a feeling of a small drop in power (even as the vehicle got warm completely) but still drives. Next trip - the situation is repeated. The next test of ATV through time and a huge loss of power from the very beginning. The engine sneezes, does not want to go more than 5 mph. What has been done: the carburetor has been replaced with a new one (inexpensive, $ 40), a new spark plug, a new ignition coil, the engine head has been removed, the piston is in good condition, valves were corrected - but the problem was definitely not in them. Ignition control unit is suspected. Who faced similar? Please help in solving the problem. Thanks in advance.

View File 2017-2019 sportsman 450/570 with eps factory service manual This is the factory service manual for the 2017-2019 factory service manual for the sportsman 450/570 with electronic power steering Submitter colin james Submitted 09/06/2018 Category Polaris ATV

Hi Anyone else with a 2017 sportsman with EPS, experiencing hard lock up with the CVT clutches. As compared to my friends 2006 Polaris 500 HO they seem to be a lot smoother engagement. Any ideas or is this normal for this model.

Well, it overheated then started blowing white smoke!! I have it torn down & the cylinder appears to be warped. Going to have the head checked out next but in the meanwhile... Does anyone have the torque sequence/specs for the head bolts?? TIA

whats do you think on over all

Charging issue? I have a 2017 Polaris Sportsman 570 EFI. Yesterday, I start the machine and it says low power (10.6-10.8). This machine is on its second battery. This is a new AGM battery with 50cca more than stock. Should I look at the regulator or stator? Thanks!!!

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.

View File 2013-2018 Polaris Sportsman and Outlaw 90 Service Manual this is the service manual for the 2013 through 2018 sportsman and outlaws 90 Submitter Cjames58 Submitted 08/23/2018 Category Polaris ATV

Hey, how's it going? I'm a new member looking to get some advice before I go to check out a '14 Sportsman 800. I wanted to get input from you guys that have experience with Polaris machines. I've been riding my whole life, dirt bikes and atvs... Honda, Suzuki, Yamaha, but never Polaris. I'm looking for advice on what I should be looking for, any common issues, really any general advice. I couldn't find many reviews of the Sportsman 800 online, so and general reviews on quality/reliability would be great too. A little info on the machine. -2014 800 EFI -640 miles, 77hrs. -Winch -Asking price is $5500 Couple add ons: (nothing major) -Aftermarket wheels with Maxxis tires -Front and rear brush bumpers -LED lights Probably going to see it in the next couple days. I'll make sure to check out all the basics... Fluids, front end, tires, suspension etc. Plus anything else you guys recommend. Thanks for any advice on advance!

Hello, Over the years I have always used a friends machine, and only ride a few times a year. Last week I purchased a 2002 Polaris Sportsman 700. The front diff needs a rebuild, the axles are very loose where they go into diff. My question is, both front wheels rotate forward by hand, but do not rotate the opposite direction. Is this "NORMAL OPERATION" I plan on rebuilding the hubs at the same time as the diff..... My question about the rear diff, it rolls as if the machine has a total POSI rear axle...……. I lifted the front end off the garage floor with overhead hoist, as I moved it sideways the rear tires skidded rather than rotate. Both would roll forward easy, but not go in a circle. When I drove the machine in the garage making a tight turn I could feel the binding and skidding of rear tires.... Even if the switch was in 4 wheel drive, when it's hanging in te air the ignition is off...….. with the machine in 2 wheel drive mode, is that HONESTLY 1 wheel drive to allow turning without tearing up the lawn? then it locks the rear axle once it's put into 4 wheel drive? I'm guessing the rear diff needs a rebuild also because there is something "BALLED UP" internally locking the rear wheels together? It's a old machine that was not maintained, I thought the wheels were all rusted, but it was 17 years off baked on red clay. Just wanting to make it a reliable machine. I have great mechanical ability, just lacking a little knowledge of what is suppose to be "NORMAL OPERATING STANDARDS" Thank you in advance for sharing your knowledge. Jeff

I have a 2018 Sportsman 570 SP Hunters Edition. I bought the quad new in August of 2018 and put around 20 miles on it with no issues. In early January of this year the quad was acting as if it had a bad battery even though it had been plugged into a tender. I checked the battery and it tested well so I took it to the dealership for warranty service. They had it for almost a month. They determined the quad had a bad EPS unit and swapped it out. Then they told me that the wire for the EPS needed to be updated as they could not program the new unit with the old wire. After the wire came in dealership told me they were still having troubles programming. After another week and a half they told me that they had consulted several times with engineers from Polaris and found a workaround and that the quad was ready for pickup. I contacted Polaris to inquire about the warranty being extended as it was in the shop for a month. They extended the 6 month factory warranty for an additional 3 months. I picked the quad up and the dealership said that the 2018 SP editions were known to have issue a with the EPS units but believed that they had fixed mine. I had it back for around a month and took it out a couple times for short rides and everything seemed fine. I parked it again for a few days and when I went to start it same issues (acting like the battery is no good and won’t start, when I jump start no power steering). Took it back to dealership and waiting to hear what the diagnosis is this time as well as their plan to fix this permanently. Just wondering if anyone else has had issues similar to mine or can give me some advice. Thanks in advance!

Just got a 2019 570 a few weeks ago, haven’t got much seat time yet but I’m loving it! I’m not new to riding but new to Polaris. I’ve had a few 4wheeler’s over the years, including a Yamaha kodiak 450 and later a Honda rancher 420.

It's time to replace the shocks and struts. Looking for some stiffer springs than the OEM as I use this for farm work and I put heavy loads on the rear and haul small trailers frequently. I've seen a couple aftermarket offerings that say they're 10% or so heavier duty. Any other options for something a little stronger / stiffer? Thanks.