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Similar Forum Topics
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By Kaz
Troubleshooting a no spark issue, was running OK, maybe a little rich, turned it off, now no spark. I've checked/ohmed out the main key switch, the start/stop switch, neutral switch, brake switch - all good. It will crank the starter, but no spark with the starter or when I try the pull start. I've checked all fuses and diodes. Swapped battery. New plug. New coil. Swapped in a used CDI - no help. Traced, removed, cleaned, reattached all grounds. Removed things like my winch from the circuits to be sure a bad relay or something was dragging it down. When testing voltages, the orange wire going from the CDI to the ignition coil shows no/very low voltage-shouldn't it have 12V on it? Sometimes I get a very weak, intermittent glow on my spark tester, but not enough to fire the plug. I've checked continuity on just about all wires in the harness. Checked/cleaned/lubed w dielectric grease- all connections, redid a few that looked old/dirty. I've checked the stator resistances, all good, but have a stator and rectifier ordered anyway, will arrive Sunday. I verified that the rectifier has a voltage output back to charge the battery while cranking - 10.5-11V, low, but expected while starter is engaged. What else can I check as part of troubleshooting? I have a Haines service manual, but the 1999 350 4x4 seems to be an odd model, there isn't an exact electrical diagram for it, but found one for another year that has all the same number of wires and same color wires, so I've referenced that. Any hints, tips or advice would be appreciated! Thanks!
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By carkivey3
i just picked this up. was told ran fine but overheating issues led to replacing head gasket and head. has not ran since. he is not a mechanic but helped someone else who he could not get back to finish job, got aggravated and put up for sale. i was thinking timing issues. i have 110-120psi on all 3 cylinders so i think valves are correct. dont know about distributor yet. however i have no spark. i have no power going to ignition coil. tried to follow white wire but gets lost in wire harness. does anyone have a wiring diagram? can anyone tell me what conditions have to be met before starting. motor turns over so i would think all safeties are met but you never know.
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By Sportsman500guy
I bought a 1996 Sportsman 500 4x4 about a month ago, and I love it. Unfortunately, I've been experiencing a few problems with the high-range gear. The first problem is that the gear selector will intermittently pop out of high and into neutral. This problem will sometimes occur when starting from a stop and sometimes will also occur while at cruising speed. The last time this happened I stopped and put it back into gear, however, as soon as I tried to throttle the machine would die. I turned it on again with no problems put it back into high and it died again. Once again I turned it on with no problems put it into low instead and it worked fine with no problem. I drove in low down the road slowly for a little and then shifted back into high with no issues.
I plan on working on it this weekend and would just like some opinions or feedback from anyone who may have experienced these problems before. I'm very mechanically inclined but im unsure of exactly where to start as this is the first Polaris ATV that I've owned. Any feedback is appreciated and thanks in advance
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By PIYIRIO
Hi all - I recently had a shop fix this quad and it hasn't been right since. The jug was resealed as it was leaking, the rings were replaced, and the valve stem seals replaced. Shop said the cylinder walls were great so nothing was done there. The motor still smokes, heavily on startup and all but quits once warmed up. Enough that I can live with it if I can fix what I came to ask about. I mentioned this work because since I've gotten it back it seems like it has power but tops out at a much slower speed than before. It's old so I don't have a speedo but I pulled out my phone at it tops out at 25 mph. I know before the work, I was getting up to 45+ mph... It's so bad, my 10 year old daughter is pulling away and straight leaving me in the dust with her governed Polaris 90.
Given the work done, what are some thing I could be the cause of such a drastic difference? I immediately thought timing but the marks appear to match up with a youtube video I found... no idea if it's correct though. It sat in another shop for 2 months and they gave me an $800 quote just for the starter... it pull starts fine.
FYI: I would take it back to the original shop to figure out but I had some issues that make them a no-go for me.
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By AnthonyT
Does anyone have a digital copy of the service manual they are willing to share I’ve looked all over the place and I can find a free copy. Thanks!!!
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