Hi guys,

As some of you know, i bought a 1996 Polaris Sportsman 500 for 800$ and it cranks and runs.

Only problem.

It idles EXTREMELY High, and the bendix, for some reason, won't kick back in once started.

The bendix works, just doesn't kick back in.

 

if your talking about the starter will not return after starting, it could be the spring in your starter drive. Remove the recoil cover and then starter drive. There is a spring inside the starter drive, its not letting it return properly, replace it.

 

If you didn't grease it when you reinstalled it,could be the problem or the garter spring as mentioned. Plus a little trick you can do after you have it repaired/replaced is to start the machine and when it first starts, "blip" the throttle quickly which will help kick the starter bendix(gear shaft )back away from the flywheel. The 500 was the only one that had this sort of problem for the most part on bendix sticking. The 700s,800s,etc have more torque when starting and kick the starter bendix back quick!
On the idle make sure the throttle slack is 1/8" only at the thumb lever and not too tight,plus there is a knurled adjuster underneath the carb to adjust the idle.

 

Well, where's the carburetor and what do i grease and with?

 

In your starter drive, there is a garter spring, grease the spring before you install a new one. by the book it says to use Polaris Premium Starter Drive Grease P/N 2871460, but i use just a little automotive grease.

Your Carburetor is usually under your fuel tank, take the seat off, and the right side engine cover, look to the bottom of the carb and you should see a adjustment screw. once the engine is running at idle, turn the adjustment screw while looking at the RPM's on your speedometer. Most are adjusted to 1200 RPM's +/- 100.

After the idle is set correctly, you can adjust the throttle.

 

Actually, i don't know what happened, but i found the carburetor and adjuster. Idles real good now. It also pushes the bendix back in. Hm.

Now gotta replace tires, lol.

Oh and, how the hell do i fix the speedometer? (Light comes on, but doesn't tell me how fast i'm going)

 

Well, i did it by sound. It sounds good, but may not be low enough, i don't know.
But Speedometer doesn't work...

 

On this first year model that the speedo cable runs off the transmission,unscrew the cable at the transmission adapter and also at the speedo and see if it turns.If not you have a frozen cable that may need a little PB Blaster that can unfreeze it or just replace it. ALSO jack the rear wheel up off the ground,crank and place in gear.While the rear wheels are turning look at the small opening in the transmission adapter and see if the inner part is turning. If it isn't then the "square wire "key" has probably snapped)that drives the speedo cable. Doesn't show to be available online,but area dealers should have it (about $10 if I remember) Look at #5(adapter) and #6 ("key') on the parts break down. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks! I'll go to my polaris dealer tomorrow and try to see if they have a speedo cable. It's not a big issue, but would be nice to be working. Lol.

 

To save you an extra trip make SURE the inner part of the adapter on the transmission the cable fits on is turning while in gear,rear tires off the ground.If it's not,get the small wire "key" for the adapter. You wont believe this small part costs this much when you see it.!