I got a 04 sportsman 500 ho with 23 hours on it, and today while i'm pounding up a knarly hill my throttle sticks whoa.......nelly!
come to find out the throttle cable is/was not roughted properly it chafed through on me.
look on your right side just behind the shifter mounting bracket ( just remove your side panel to inspect) now i'm shure i'm going to have a fight on my hands trying to get this covered under warranty. Does anybody know if this is covered under warr? has anybody ran in to this issue?
just a little fyi for you 500 ho owners.[img]i/expressions/face-icon-small-shocked.gif[/img]

 

I had one issue so far with my scrambler, on the first ride on the scrambler I had the stearing bolt nut fall off on the first ride, the quad still rode but it was a damper since it was the first ride, cheap fix and Ive been out twice since without any problems. Anyone deal with the dynojet kit for the 4x4 scrambler? I just received mine off of ebay and I will order my pipe probably this week. I want to order the HPD, is the 300 dollar price tag right?
Thanks

 

I called my local dealer about my throttle cable, and this is starting to become a common problem.
they ordered the cable and are going to warranty it.............and they havent even seen my quad yet!
they told me when the cable gets in, then bring my quad in.[img]i/expressions/face-icon-small-happy.gif[/img]
I also checked 2 of my buddys quads and the throttle cable is roughted the same way.
so we cut a piece of 1/4 inch vaccume hose and split it down the middle, then put it around the throttle cable to prevent chafing.

 

71stang99


Please let me know what you find out about the dynojet kit and what all it includes. And how complicated is it to install.



Thanks,
Nez

 

Wrenchnnutz just wanted to say thanks for the heads up ,I checked the cable on my 04.5 ho yesterday and sure enough the cable was half worn through where it was rubbing on the frame and the quad only has 14 hours on it ,cut a piece of windshield washer hose down the middle and put it on the cable and then put a couple of plastic tie wraps on it to hold it ,good to go.

 

WRENCHNNUTZ..WHERE ARE YOU LOCATED IN OHIO???WHO IS YOUR DEALER..I JUST BOUGHT A NEW 2004.5 400 SPORTSMAN...I LIVE IN LODI AND DEAL WITH BAIR'S IN NORTH CANTON...

 

I just picked up my new 2004.5 500ho on Saturday. I looked at it, and the cable is touching part of the frame behind the shifter- is this where it is rubbing and causing the problem? If so, I'll have to protect my cable somehow too. Thanks.

 

sharkypaul ,I would put some sort of protection on the cable anywhere that you see the cable touching the frame or anything else for that matter,cheap insurance.

 

Is this on the 04 500ho scrambler too?

I checked mine and didn't see the cable anywhere!

 

Just got mine back from the dealer (http://www.lissyspolaris.com/ ) [ the best dealer in Illinois!!  ]… they replaced the cable and added a small piece of rubber hose to help protect it … the dealer said a Polaris tech was down to take pictures of the issue. Hopefully they will get a fix out to the rest of you. With only 224 miles / 30 hours the cable was nearly wore though.