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-   -   2004.5 Polaris Sportsman 400 (https://atvconnection.com/forums/polaris/356028-2004-5-polaris-sportsman-400-a.html)

Geartec 04-10-2014 08:30 PM

Ok i did another ohm reading on the pickup coil i have 5 settings 200 shows a random number then goes to 1., 2000 shows 457, 20k shows 0.47, 200k 00.4, 2000k shows 001 . On my carb the diaphragm slide is sticking is there a way to clean it i tried carb cleaner then oil but it still sticks. last year in the summer it was working fine.

old polaris tech 04-11-2014 05:24 AM

Then try a new pick up coil and see if it solves the problem since you done everything else except a leak down test. On the slide,simple wally world carb or electrical cleaner for the slide and the jet block should stop the sticking.Check for any rough/worn spots on the slide and jet block along with any worn places on the diaphragm itself. After the spring and cap reassembly,the slide should raise up and snap back easily with your finger with no sticking.If it doesn't,could need to be replaced.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

Geartec 04-11-2014 08:55 AM

I checked the timing again its good, the slide on the carb I found a small piece of varnish in the corner cleaned it all now it slides freely. I found 6 cut wires that connect to the Resistor module transmisson shifter but did not find a Resistor module it supposed to be under the seat, would this affect the quad not starting?

old polaris tech 04-11-2014 03:28 PM


Originally Posted by Geartec (Post 3243644)
I checked the timing again its good, the slide on the carb I found a small piece of varnish in the corner cleaned it all now it slides freely. I found 6 cut wires that connect to the Resistor module transmisson shifter but did not find a Resistor module it supposed to be under the seat, would this affect the quad not starting?

Say what?? :) If you're talking about the transmission switches wiring that are cut (item 43 and 67) Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
And the resistor module missing in the harness.Item#4.http://www.cyclepartswarehouse.com/f...2004&fveh=5631 then sounds like you need to take time repairing the harness of any problems or just break down and get a new complete harness and go from there. And yes anything like this can cause problems from ignition,charging,etc..

Geartec 04-11-2014 11:42 PM

sorry i meant Under the pod there are 6 wires cut with no plug the wires coming from the transmission shifter are there plugged in so i just need the resistor module.

Geartec 05-27-2015 11:50 PM

Well here is a update now that i had some free time i replaced the pick up coil and adjusted the carb (pilot screw) now it is finally running thanks everyone for the tips now onto my next project!

old polaris tech 05-28-2015 09:52 AM

Only took a year to fix it.. :) Glad it simple pick up coil..

Geartec 05-28-2015 10:55 PM

:lol: it was during the winter when i ordered the pick up coil, then when it finally got warm i installed it


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