[Lucas_logan]

Hey! I was wondering if anyone on here would know the solution to an issue that I'm having with my machine. The quad is a 1999 Sportsman 500 and it had a problem today. I had the throttle just about maxed in low range and was not moving. I assumed the belt was slipping because it had been left outside in the rain for a few days, and there was a bit of water coming out of the CVT cover, but then even after the CVT was dried, it was still having the same issue. Like it would start going across a field, then I would give it any amount of throttle and it would make a noise then slow right down as if it was in neutral. And then it will randomly kick back in and then the engine braking will just about throw you over the handle bars. Anyone ever have this problem? I assume it's the belt that's just about to go or the clutch is gone. Idk what it is anyone have advice? Thanks in advance

 

[FPD218]

Pull the clutch cover off and have a look....

Welcome to the forum!

 

[latebird]

I suggest you have both the primary and secondary clutch serviced and perhaps a new belt while you are in there.

 

[John.smith3332]

I have a problem with my 1996 Polaris 500. With the Key in the on position it’s sputters at low speed as well as Under power. When I turn the key between the on in the off position it runs just fine. I put a new key assembly in and it does the same thing. What else could it be? Any help would be appreciated

 

[latebird]

I have a problem with my 1996 Polaris 500. With the Key in the on position it’s sputters at low speed as well as Under power. When I turn the key between the on in the off position it runs just fine. I put a new key assembly in and it does the same thing. What else could it be? Any help would be appreciated

I see you double posted and hitchhiked on different threads looking for an answer - it would have been more productive to have just started a new thread with your question.

However, to test the key switch as the source of the problem, start the engine and unplug the wiring harness from the switch - if it runs fine with the switch unplugged in, you have a faulty switch. It's that simple! If it still sputters with the switch unplugged, then the problem is one of the other kill devices: throttle safety switch, handlebar kill switch, reverse speed limiter or a short in the black kill wire to ground somewhere. You can test the reverse speed limiter by holding in the override button - if the problem is gone when holding the button in, then look no further.

Let me know what you determine.

 

[John.smith3332]

Thanks for the tip. It turns out it is the reverse limiter switch just as you suggested. Is there a way to override the switch?

 

[latebird]

It's not the reverse limiter switch, but the reverse limiter module.

The module determines engine speed with a feed from the alternator. Depending on how you want to fix it, you can simply defeat the reverse speed limiter by unplugging the black wire from the module, but be aware and use caution as doing so will allow the engine to rev as fast in reverse as forwards. It's your life and your decision, but if you defeat the limiter, don't let other people operate the vehicle.

 

[John.smith3332]

I followed the switch and on plugged the pink wire. It seem to correct the problem. It runs fine in reverse and forward. I understand the possible danger of someone not knowing the power in reverse.Am I OK leaving the pink wire unplugged?

 

[latebird]

Yes - the button just will not function anymore and the AWD may not work, may not work in reverse, may be full full time AWD in both forward and reverse or some other issue that I cannot foresee.

 

[John.smith3332]

What part do I need to properly repair this issue?

 

[latebird]

Part number 4060135 which was superseded to 4060205 - but neither is available from Polaris - it is referred to as the LR-83 Hub Safety Switch module - you will have to search Ebay and salvage yards to try to find one.