Top 20 Polaris 2004 Sportsman 500 H.O Questions & Answers

Question edited for clarity. Question moved to a Polaris Category. Normally, you would just drain the tank, remove the fitting and replace the gasket. I don't see a gasket though, unless it is just a standard O-ring. That is the way to do it though. https://www.google.com/search?q=1999+polaris+sportsman+500+fuel+tank+gasket https://www.google.com/search?q=1999+polaris+sportsman+500+fuel+tank+leaking+from+bottom ..

Question edited for clarity and typos, and guessing it is a 'Polaris' and not a 'polar'. Question moved to model category. It is a known issue. You likely need a new switch, they burn the contacts with prolonged use. https://www.google.com/search?q=1999+Polaris+Sportsman+500.+Why+will+it+not+turn+off

check fuses and connections https://quads.ddns.net/service-manuals/polaris/

go to an oem parts supplied like cheapcycleparts dot com and they'll cross reference them

There is a fuse link at the Positive battery terminal wire. It will blow to protect the circuits if the battery is hooked up backwards. It is a smaller gauge section in the wire that melts to save systems. any auto parts store has one MDS

clean your carb, look for air leaks between motor and air filter.

VIN to Year Chart ALLDATA Support 10th digit = year

My 2005 Polaris ATP 500 requires I depress the right foot brake while shifting into reverse or down into low range. Perhaps some adjustment on the foot brake to make this work. Also check linkage to make sure it is not binding. Others say if the idle speed is too high, you may not be able to shift. Try shifting with the engine off to see if it goes into the gears, using the foot brake. If yes, try again while at low idle speed.

maybe a new battery may help ?

howdie check the vacuum lines and make sure the module is workin should be fuse for it and check for linages are engaging or the transfer case might have broken chain could be that how MAny Km,s does it have ?

My 2005 polaris Sportsman 500 does this in the winter when plowing, but only sometimes when pushing the override button to go backwards in 4x4. A friend told be to check the differential fluid levels in the rear for my machine. Have not done this yet.

If it is stuck, try to rock it back and forth while attempting to shift. This has worked for me in the past. It sounds like oil wasn't replaced after going through mud / water before storing.

I have a 2001 polaris sportsman 500 H.O. I have replaced the fan and the thermial fan switch,and checked the thermostat. Everything is either new or works there are no bubles in the coolant when its running I am running out of opptions . If I unplug the thermal fan switch and plug a jumper wire in the fan will run. I thought the new switch was bad and I tested it and it is good

Does the cooling fan ever run when the engine is hot? If not, you may have a problem with the fan thermostat. For the record, spray carburetor cleaner does no good if it's sprayed on the outside of the carburetor with the engine running. That's not what it's for.

sounds like the coil is weak or the electronic spark box is goin fuel filter been changed ?right gap on the Plugs? need more imfo on it to do more thks

This is caused by a bad needle and seat in the carb you can buy a carb kit and replace the needle and seat and it will stop leaking make sure not to bend the float

Clean and lightly oil the brushes in the starter motor,common prob. they get sticky.

check atvconnection or quadcrazy forums

it sounds like your starter solenoid is stuck. Locate the solenoid and check for continuity between the positive and negative poles right on top of it. If there is continuity between the poles in the off position, your solenoid is stuck and probably needs to be replaced.

check in ignition system.something heating up.