Top 10 Polaris ATV Questions & Answers

Can i get a wiring diagram for a 2004 polaris sportsman 500 H.O. i get no powere anywhere. [email protected]

for a 2001 polaris xplorer, you need to remove the body, the drive belt cover, both the drive clutch and the driven clutch. to remove the drive clutch I went to napa auto parts and bought a 3/4 x6 inch fine threaded bolt. I removed the bolt for the clutch. I then inserted 1 long and 1 short 12mm sockets into the center of the clutch. then threaded the 3/4 bolt until it was tight gave it a few light wacks with a small sledge hammer, turn it some more and it popped right off. alot easier than buying the polaris puller. the driven clutch came right off no problem. you need to remove the back palstic part of the drive belt case. three bolts behind where the driven pulley was and another screw connected to the foot rest. make sure you remove the negative battery terminal. you then need to unscrew the bracket on the back of the starter and remove it. next I stood the quad up on its rear tires and back frame.Put an oil pan orsomething underneath the back frame bar as some of the premix oil leaked while it was in this position. remove the skid plate. pull back the rubber boot on the starterand remove the wire. go back around to the side and remove the two hex headed screws from the back of the starter. at this point the starter housing should come right off. then I pulled it out. I replaced it in reverse. make sure the o-rings are on correctly. I really hope that this helps some of you out there. One note I purchased an aftermarket starter that was connected to a cast aluminum housing that i assume houses the pinion gear. but i had to remove that part and only install the back part of the starter.

my polaris outlaw 500 sarted cuting out last ride could not ecerate past 1/4 throtle and was back fireing so went to fix and wont run at all i have spark, plug is wet, changed fuel, seems to have compresion, when it turns over it tries to fire at times more like a hickup almost stops the sarter and a puff of smoke out the carb. im about to tare it down any ideas whats wrong ? bike was hard to start but ran ran perfect killed raptors with ease. bike was bored and built by some shop before i owned using ktm sleave and piston ? motor says nicols 520. didt over heat or make noises. have tried cleaning carb, jeting no luck please help

Solution#1 worked perfectly. It only took about 15 minutes all together.
the side panel removes easily. It just slides out of the other panel. Once you have removed the handle (Shifter) and the other two bracket bolts, just place it back into the shifter housing and move it around. I was amazed at how easy this was to repair. I also turned the ignition to the on position to see if it was changing gears and it was.
Solution #1 repost originally posted by Jpach
I tried this today and it worked. Pull the sideplate from the ATV so that you have access to the gear shifter assembly. Unbolt the gearshift assembly from the mounting bracket. There are two bolts at the rear near the two rods that exit the assembly and three on the bottom. When the bolts are out, remove the assembly from the mounting bracket. Hold it in your hand and move the shift lever through all of the positions. This won't actually shift the transmission, but it should free up the rods in the assembly. Remount the assembly with the five bolts and it should now be able to shift out of reverse.

If your speedometer is broken then your AWD will not work. You can do 2 things

1. Replace the Speedometer
2. Remove the 6 pin plug from your speedometer
On the plug, short the brown/Brown White wires together and
tape it up good.
Do not reconnect the plug.
You will lose the function of the speedometer but your AWD will work.

this sounds crazy but is your speedometer in working order. i have a 99 also and i didnt get any spark one day just quit. after a couple days of trying things i read on the internet about if your speedometer is not working and cutting on or off it will short out the spark and also make the 4 wheel drive not work. i unhooked the speedo and no problems since.

check the exhaust lobe on the cam. these are prone to wear if oil changes are neglected. try to run it with the airbox lid removed and see if there is any change.

if the 4-wheeler is just clicking when you try and start -- this is a good indicator that the voltage is not high enough to activate the starter,, and the sound that you hear is the solenoid clicking.
try and jump the four wheeler battery with a car battery,, this should give it the power it needs to turn over. as soon as you have the ATV running - ride it around for awhile and let it run and charge the battery, there is also a chance that the battery is going bad and it may be time to buy a new one,, also make sure the generator on the ATV is charging the battery at a voltage of 13.6 to 14.4 volts DC. IF jumping the battery still does not start the machine and it still just 'clicks',, then the solenoid itself could be at fault -- replace it and then try and start..
(( use a bench charger to fully charge the battery and re-install into the ATV and you should be back on the trail in no time at all )).

c...

I have 2004 1/2 700 sportsman that had the same problem. The circuit breaker is in front of the handle bar, under the plastic cover. you will have to remove front luggage rack if you have one. Look at the wire harness and locate a plastic sealed rectangular holder about 3 inches long. It is automaticly reset when it cools down.
I kept having power loss that could be restored by tapping on the plastic holder.
I cut it open and found the connections corroded on the 20 amp circuit breaker inside. Seal plastic up if you cut it open to keep it from shorting out and to keep moisture out.

In 2000 they had two - the 'early' and the 'late' 2000 diagram - pretty sure the late diagram would be close to exact to the 2001/definitely didn't reinvent the wheel between 2000 and 2001 - good luck