I have a new 04 Sportsman 400. The bike runs great but in high at 6500 rpm I'm doing only 25-30 mph. Is that normal?? Are they governed?? What is the redline?? Any info is appreciated.

Shady

 

There is something wrong,sounds like the belt is slipping or something else wrong in the transmission,R U sure that you are high gear,not low?

 

is this your first polaris automatic?

 

Shady,

You have a problem and get it to the dealer before the 6 month warranty runs out. I also have a 04 Sportsman 400, I was smart in purchasing the extended 6 month warranty when i bought it.

With 100 hours on it and at 7 months of owning it, my driven clutch came apart (two pieces), it unthreaded and left me stuck on the mountain. My friend towed me home, (I found "The Way Out"). The atv was in the shop for two weeks to replace it and the belt. I got it back and it went sour again, at 106 hours the primary cluth failed. The atv would over rev in low or high and then engage in the desired speed for the range that was selected. They changed the buttons in the primary clutch and back home I went. I ran the atv for another 8 hours and it went south again. This time when in high, it would act like it was in low and then the belt would grab and go into high (almost like a passing gear in a car). It is currently in the shop and they will rebuild the primary clutch again.

When the driven clutch went bad, the service manager wanted me to pay for another belt. I told them Polaris has a limited lifetime warranty on the belt. I did not cause the belt to go bad, the clutch failed and it was the cause of the belt needing to be replaced. It took a phone call to Polaris to get the belt replaced under warranty. While I was on the phone with Polaris, they called the dealer and ok'd the replacement belt.

The dealer told me my problems were rare and so far there has been no cost for me to repair these clutches. So far the atv has been in the shop 3 weeks and that does include the current clutch issue. The dealer has been great since the call to Polaris, I just do not trust my atv now. Every week it is wanting to go to the shop. I think it likes another atv at their shop. I will say, it is like a gold digging girlfriend that you are madly in love with. I have other related repair expenses I will not list now...

 

Wow PAatvr, I have never heard of such bad luck. That is rare!

Schaede, that sounds like a clutch problem to me, take it in emediatly!!!

 

PAatvr,
sounds alot like your dealer doesn't know how to work on those clutches! We have thousands of miles on our polaris machines and have never had a clutch problem!! When the dealer gets it figured out, it will be good and not leave you hanging. Ask him if he is doing the alignment on the clutches when the work is done.

Schaede
Sounds like you might have a broken spring in your secondary, but I am just kind of guessing. Deffinately get it into the shop and get it looked at!! These clutches are pretty easy to understand once you look at them, tuning is a different story but there basic opperation is pretty straight forward. Talk with your dealer and ask him to show you the problem when he gets it figured out, so you can see wahts up.

Chris

 

I had a 04 400 sportsman and had a similair problem out on the trails one day. Mine starting jerking and didn't want to go right. Found out it had an a broken front motor mount and caused the belt to burn. It kept locking up in reverse. I had nothing but problems with my 400 so I traded for a 04.5 500 HO and it has problems as well. I am about ready to give up on Polaris. Dobie