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Recent content by micoviso

  1. Replacing front CV axles, what else should I do while I have it apart?

    ATV Repair and Maintenance
    I didn’t see changing the front gear case oil in that list. If you’ve never changed it, and this ATV is new to you, it probably needs changed. Also, not sure if the ‘98 has the same spaghetti mess wiring circuit board as my ‘97, but I cured several intermittent problems by taking a pair of...
  2. 99 Sportsman 335 won’t start

    ATV Repair and Maintenance
    Saved the link. Thanks.
  3. 2004 Sportsman 500 (Early Model) “cold blooded”

    ATV Repair and Maintenance
    Wow! Adjusting the valves made a huge difference. I don’t have a gauge small enough to tell what they were set at, but I’m guessing around 0.002. After I set them to 0.006, it starts much easier with less choke, stays running, and warms up quicker. Not as perfect as my others, but much better.
  4. 2004 Sportsman 500 (Early Model) “cold blooded”

    ATV Repair and Maintenance
    Wasn’t expecting that answer. But, I guess that’s why I’m on the forum, to pick the brains of people who know more than me. I’ll check them as soon as the temp gets above 30 here. What should I expect to find that is causing this, too big a gap, or too small a gap? My guess is too much gap...
  5. 2004 Sportsman 500 (Early Model) “cold blooded”

    ATV Repair and Maintenance
    I’m finishing up restoring a 2004 Sportsman 500. It runs great once warmed up, but compared to my other 3 similar Polaris ATVs, it seems sort of “cold blooded”, meaning it doesn’t start without choke when cold (the others all fire right up on all but the coldest mornings without choke), and it...
  6. AWD not engaging on right side

    ATV Repair and Maintenance
    That was it! The spacer on the Hilliard clutch was frozen in place and wouldn’t allow the clutch to come back far enough toward the armature to engage. At first I thought it was just dirty from neglect, but it wasn’t. It was actually pressed in there and wouldn’t move. I had to actually heat...
  7. AWD not engaging on right side

    ATV Repair and Maintenance
    My plan was to switch the hubs between non-working and working sides, and I will follow through on that, but when I took both sides apart and looked at both Hilliard assemblies, I found that the spacer in the non-working side is stuck in the clutch. It does move or come out easily like the...
  8. AWD not engaging on right side

    ATV Repair and Maintenance
    Really!!! I had no idea. I did have them both off. I’m working on a early 2004 Sportsman 500 HO. Is that the case for this model? I never noticed a marking, but then again I never looked for one either. But if they’re reversed, wouldn’t that make them both not work instead of just the right...
  9. 2004.5 Sportsman 500 HO- AWD not working- Not sure where to start looking??

    ATV Repair and Maintenance
    There are several threads on this forum with comprehensive troubleshooting instructions for this problem. If you search for AWD or 4WD they’re pretty easy to find.
  10. 2004 Sportsman 500 Wheel Hub Condition

    ATV Repair and Maintenance
    I’m tearing down the front end preparing to replace my strut housings (early model). In looking at my Hubs, the races all look fine. I’m assuming they were replaced at some point. However the inside surface of the hub, that the Hilliard clutch uses looks different on each hub. One is very...
  11. AWD hub seal and coil rebuild

    ATV Repair and Maintenance
    Bummer. Ok, thanks for the info.
  12. AWD hub seal and coil rebuild

    ATV Repair and Maintenance
    I have an Early 2004 Sportsman 500 HO. AWD light comes on in the speedo (flickers actually), but when raised off the ground, AWD does not work. I tested the handlebar switch and a few other things that seem to be fine, but When I unplug my AWD coils and put an Ohm meter on them, I don’t get any...
  13. Change front lower control arm bushings

    ATV Repair and Maintenance
    I’m already prepping for operation zerk. The back end is all together, so I’m taking a silver sharpie and putting dots where all of the grease zerks will go. If I can get to it with a sharpie while everything is assembled, I’ll be able to get to it with a grease gun hose.
  14. Change front lower control arm bushings

    ATV Repair and Maintenance
    Thank you
  15. 2005 Polaris Sportsman 90

    ATV Repair and Maintenance
    You probably can't (find someone in your area). The dealers in my area just laugh and point me to the showroom any time I tell them what I'm working on. Problem is, I love these old beasts and don't want their brand new shiny objects, or the price that comes with them for 4 machines for my...
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