Polaris 2005 Sportsman 500 H.O - Answered Questions & Fixed issues

http://www.linnbenton.edu/auto/perform/no_start.html Engine Won Crank or Start Troubleshooting Car That Won Start What to Look For When You Just Can Get Your Car to Start Each of the LINKS above troubleshoot car problems. Good Luck.

I think you may have a stuck float in the carburetor.

You need to put a gauge on your fuel pump to test your fuel psi just because you have gas to your injector doesn't mean you have the right amount of pressure.

Rebuild it before you do more damage! If you keep riding it the cost of the rebuild will be more than the machine is worth!

sounds like the connecting rod on the crankshaft. i would inspect the primary clutch first before an engine teardown. Sometimes the engine shifts on the engine mounts and the clutch hits the cover, also check to make sure belt is not slapping around in cover.

Check your u joints or CV joints. Does the clicking speed up when the ATV speeds up? does it click worse when turning? Is there a stick or something jammed up in there somewhere?

sounds like u need to change your hub fluids and or clean the meatal rings in the hubs so the electro magnets will engage your hubs efficiantly

stator pickup or stator coil

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

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

Question edited for clarity, correct order and add maker. Question moved from Cars and Trucks to model category. Service manual https://www.manualslib.com/products/Suzuki-Kingquad-5901790.html ..

https://www.motosport.com/atv/oem-parts/suzuki/2004/eiger-400-4x4-auto/wiring-harness

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

Question edited for clarity.

SHI0206 - Kawasaki & Polaris Diesel UTV Starter

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