20 Most Recent Arctic Cat 2004 500 4x4 Automatic TRV Questions & Answers

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Your floats are stuck or needle valve not seating properly, clean carbs, set floats and go riding. Ck fuel lines too first.

sounds like it has been sitting, if you have never rebuilt a carb, best to bring it in,, the main jet is probably all gummed up,, you can try draining all your tank gas,, spraying carb cleaner into the carb after removing air cleaner but that really wont help out the main jet.. Stabil is a good product for gas if you are going to store your ride for awhile, it also acts to clean carbs while using a small amount when you fill up.

The starter has to throw it's gear out using centrifugal force. The speed of the starter has to be enough to overcome the spring inside. It is either a little seized and needs to be rebuilt and greased up, or the battery isn't powered up enough to get the right speed to engage properly. In that case clean the battery posts and clamps well, then charge or replace the battery. To know if the battery is bad wait till it is charged... if it still doesn't engage try again with booster cables from your car etc. and see if it suddenly works fine.

Sounds like you blew the fuse under the seat here are the service manuals for all Arctic cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

Sand it down and repaint

Sounds like the gear is stripped in the box by the front housing here are the service manuals for all Arctic cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

weak fuel pump, choke not working ? Here are the service manuals for all Arctic cat ATVs

Bad timing ? water in the fuel. here are the service manuals for all Arctic cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

Adjustment between the shift lever and gearbox here are the service manuals for all Arctic Cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

Common problem is there is water and dirt that gets inside the actuator and it strips the plastic gears inside. Here are the service manuals for all Arctic Cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

Sounds like the thermostat is not opening Here are the service manuals for all Arctic cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

Here are the service manuals for all Arctic cat ATVs Parts House Lawn Mower Parts and Chain Saw Trimmer Parts

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Assembling a recoil system on a Polaris 400 Xplorer involves several steps. While I can't provide an actual diagram here, I can outline the general steps involved in assembling a recoil system:

1. Preparation: Ensure you have all the necessary parts for the recoil assembly including the recoil starter, recoil housing, recoil spring, and any other associated parts.
2. Mounting the Recoil Housing: Begin by mounting the recoil housing onto the engine. It typically bolts onto the engine casing.
3. Inserting the Recoil Starter: Place the recoil starter mechanism into the recoil housing. It usually fits into grooves or mounts within the housing.
4. Attaching the Recoil Spring: Connect one end of the recoil spring to the recoil starter mechanism and the other end to a fixed point within the recoil housing. This provides the tension necessary for the recoil starter to function properly.
5. Installing the Pull Cord: Thread the pull cord through the hole in the recoil starter mechanism and tie a knot at the end to secure it. Wind the pull cord around the recoil starter as per the manufacturer's instructions.
6. Testing: Before completely sealing the recoil housing, give the recoil starter a few pulls to ensure it functions smoothly and retracts properly.
7. Final Assembly: Once you're satisfied with the recoil assembly, bolt down any remaining covers or components to secure the recoil system in place.

Always consult the specific service manual for your Polaris 400 Xplorer for detailed instructions and diagrams tailored to your exact model. Additionally, if you're unsure about any step, it's best to seek assistance from a professional mechanic or someone experienced with small engine repair.

take off the horn unit power it direct if it works its ok, if not replace, next step wire a small bulb into the horn wires and press the button if it lights the switch is ok, if you have a circuit tester put one end on the battery ground and check for power in the horn wires if their is power there put the lead on battery positive and press the horn button if there is no power their the switch or wiring is faulty

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