Polaris 2005 Sportsman 400 - Answered Questions & Fixed issues

It sounds like the external coil is bad.

Bottom of motor, look for a cut out in the skid plate and there should be the plug

most likely a fuel issue. has it been sitting up ? if so if its got a carb it prob gummed up, pour some seafoam into the gas tank with fresh gas and run it, try and keep it running with the throttle, it might clear some varnish out the carb if it not too bad, if tht dont work and it is a carb engine then the carb will have to be removed and cleaned. if it a FI engine then you got a bad full pump more than likely If you need further help, reach me via phone at https://www.6ya.com/expert/allen_b068623c5003aa4b

Mice love to build nests in 4 wheelers.Seen it dozens of times.They also love to chew on the wires.Look aroundunder the plastic,bet youll find one.

check wire plug on handle bar most likely corroded unplug and sray with bat, cable cleaner and try

This is not normal. You should have a dealer check into it. An electrical issue can be 5 minutes or 5 hours or more to find. Sounds like a ground is bad somewhere. Check the battery terminals.

The Display screen on your Speedometer should indicate if you are in P , N , L or H .It should also indicate if you are in 2 or 4WD

If the shocks are worn out, get off the machine and lift up on the back rack. This takes up the slop between the shifter box and the transmission, and usually allows me to shift. I also had an issue with the thin steel plate behind the shifter box. Got a crack in the top , so it was flexing, creating more slop. Welded it shut, good as new.

isnt that a 2 stroke? go to polaris for an owners manual

Sounds like a bad regulator.

what?? it just bolts on??

don't worry about it if everything works properly!

interesting problem

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It is inappropriate to explain how to possibly steal a machine on this public site.

Assembling a recoil system on a Polaris 400 Xplorer involves several steps. While I can't provide an actual diagram here, I can outline the general steps involved in assembling a recoil system:

1. Preparation: Ensure you have all the necessary parts for the recoil assembly including the recoil starter, recoil housing, recoil spring, and any other associated parts.
2. Mounting the Recoil Housing: Begin by mounting the recoil housing onto the engine. It typically bolts onto the engine casing.
3. Inserting the Recoil Starter: Place the recoil starter mechanism into the recoil housing. It usually fits into grooves or mounts within the housing.
4. Attaching the Recoil Spring: Connect one end of the recoil spring to the recoil starter mechanism and the other end to a fixed point within the recoil housing. This provides the tension necessary for the recoil starter to function properly.
5. Installing the Pull Cord: Thread the pull cord through the hole in the recoil starter mechanism and tie a knot at the end to secure it. Wind the pull cord around the recoil starter as per the manufacturer's instructions.
6. Testing: Before completely sealing the recoil housing, give the recoil starter a few pulls to ensure it functions smoothly and retracts properly.
7. Final Assembly: Once you're satisfied with the recoil assembly, bolt down any remaining covers or components to secure the recoil system in place.

Always consult the specific service manual for your Polaris 400 Xplorer for detailed instructions and diagrams tailored to your exact model. Additionally, if you're unsure about any step, it's best to seek assistance from a professional mechanic or someone experienced with small engine repair.

take off the horn unit power it direct if it works its ok, if not replace, next step wire a small bulb into the horn wires and press the button if it lights the switch is ok, if you have a circuit tester put one end on the battery ground and check for power in the horn wires if their is power there put the lead on battery positive and press the horn button if there is no power their the switch or wiring is faulty

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https://www.polarisatvforums.com/threads/2006-polaris-sportsman-500-efi-not-getting-power-to-the-fuel-pump.191336/ This thread should help you.