Hello All,

Im new to these forum's and have done some research on quite a few problems, I've been having with a 2004 polaris sportsman 500HO. The machine when purchased had 120hrs on it with under 1000 miles. Due to the machine sitting so much the carb had gummed up and started leaking gas from the overflow. The local polaris dealer insisted I needed a carb re-build kit and not just a float/needle. After that was completed and took it out for a test drive - I noticed the breaks were failing to enguage. Back to the dealer the machine went and he adjusted the position of the fluid res on the handle bars and bleed the lines for me. He also noted that the machine RPM was adjusted higher at idle, *1100 RPM* to avoid the belt slipping on me. The machine was probably out for 2-3 more trail rides and put away in a garage before winter hit. Upon trying to take the atv out in December it wouldn't start via the starter and the pull cord when ripped never re-tracted back inside the unit. Back to the dealer the machine went for a new starter and apparently discovered water was inside the assy where the pull cord lies *freezing causing it not to retract* housing removed all water drained and new seal placed. The ATV now had issues going from F-R-N and would get stuck between them. (Removing the linkage and manually forcing it back fixed this). I decided to replace the shifting box. On the next trail ride I noticed the 4WD on demande wasn't enguaging the TACK is lit and speed is being calculated. A little diagram of 4 wheels appears when in high or low but only the rear wheels are driving the unit. I'm tierd of spending money into this machine - polaris has been nothing but issues since day one. Would anyone have any advice on fixing the 4WD * dealer is stating I need a new taco meter*. I've read through previous thread's and there is a quick fix with the brown and white wire - not sure if this taco that seems fully functional is the same issue. I would hate to rip the brown and white out of the guage cluster for no reason. Only 145hrs on the unit 25 hrs since purchase ..... in need of help!!

Thanks in advance

 

Sorry for the bad luck,but can happen with any machine! Plus some dealers sell as is and don't do a thorough check of all units that are traded in or on consignment. As far as the awd just jump the brown/white speedo wire to the brown or you can jump it to where the browns (ground wires) tie together under the front panel. You may or may not have the function of the speedo. OPT

 

To my understanding in 2004 models the 4x4 is enguaged through the cluster - in removing the wiring mentioned above, I will not loose existing functionality of the cluster? Also, by joining these two wires together is that implying that 4x4 is always on enguaged or will the switch still be functional? When the ATV was last dropped off for service at the dealership 4x4 was functioning, upon it's return of the starter repair it wasn't. Could they have possibly disconnected something in that process, that might result in this issue? Is the both front wheels not driving almost always due to the guage cluster? Is there something I may not be looking at - trying to avoid returning the machine for 70$ diag charges. The dealer indicated the only way to troubleshoot the cluster, was to order a new one to test with 400$ charge. I'm assuming he's just very busy and won't take the time like a DIYer.

 

Dealers wont and don't have the time to trouble shoot as the speedometer unit is considered "non repairable" to Polaris and the dealers because they are sealed!. Some posters have gone in to the circuitry of the speedo and replaced resistors and such! All I can tell you is from the schematics is the resistor in the speedo shorts out not allowing the brown/white wire to complete the "grounding path" for the awd. "Fixes" are just pulling the speedo connector and jumping the brown/white wire to a "known good ground" which is the frame or brown wire.Some have said to leave the connector unplugged(losing speedo function) and that you will have full time awd on standby(it's like by passing the switch) and will work as the system normally does(front wheels engage when the rear wheels slip) You also might try jumping wires at the awd switch itself as one member did this on his machine that didn't have a speedo and regained the awd.(Magnum I think?) I did what every other tech would do when I was at the shop and replaced speedos. OPT