How to Repair a Polaris Four Wheeler

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Almost every vehicle needs regular servicing and repairs in order to continually perform at its best, and Polaris' lineup of four wheelers is no exception. The company has released dozens of ATV makes and models throughout the years, ranging from sporty racing quads to youth models to heavy-duty utility ATVs. Despite the differences between the company's many makes and models, general repair tips and troubleshooting instructions remain consistent for all Polaris four-wheelers. The electrical, ignition and fuel systems are some of the most common sources of Polaris ATV problems.

Things You'll Need

  • Wrench
  • Multimeter
  • Replacement fuse (amperage varies according to make and model)
  • Mixture of 1 cup water, 1 tablespoon of baking soda
  • Replacement battery
  • Separate battery charger
  • Spark plug wrench
  • Replacement spark plug
  • Wire thickness gauge
  • Spark plug gap tool
  • Fresh unleaded or leaded gasoline
  • Engine oil
  • Replacement fuel vent lines

Electrical

  • Use the quad's starter and listen. If the engine fails to turn over, begin assessment and repairs of the electrical system.

  • Inspect the quad's main fuse. For Polaris four-wheelers, the fuse box is typically located next to the battery case, underneath the Polaris seat and steering shaft. Remove the main fuse and use a multimeter to determine if the fuse is good or bad. Typically, if the multimeter beeps after touching both ends of the fuse, it is still good. If not, replace the fuse with a new one of the same amperage.

  • Inspect the battery. Again, remove the seat bolts and seat to access the battery. Remove the battery by undoing the holding straps, removing the battery vent tube if it is a conventional battery, disconnecting the black battery cable followed by the red one, then lifting the battery carefully from its case.

  • Replace the battery if it is damaged. Each Polaris ATV owner's manual lists the voltage of battery needed for a particular quad, located within the "Specifications" of each manual.

  • Clean the battery terminals if they are dirty. Use a solution of one tablespoon of baking soda dissolved in one cup of water for this cleaning.

  • Charge the battery fully using a separately powered battery charger.

  • Reinstall the battery, this time connecting the red cable before the black one. Reinstall the seat and its screws.

Ignition

  • Inspect the spark plugs if the engine does not run correctly, misfires or if it turns over but fails to start.

  • Remove all spark plugs, located within each cylinder of every Polaris quad, by taking off each spark plug cap and turning each plug counterclockwise with a spark plug wrench. Again, the quantity and type of spark plugs varies according to the particular Polaris model and make.

  • Inspect the insulator tip of each removed spark plug. If the tip is blackened, burnt or damaged, replace the plug with one of the same type.

  • Measure each plug's spark plug gap and make sure that it is set to the width recommended for that particular Polaris ATV model in that quad's owner's manual. If not, use a spark plug gap tool to set the spark plug gap accordingly.

  • Reinstall the spark plugs and restart the engine.

Fuel System

  • Ensure that the gasoline levels in the fuel tank are adequate and that engine oil levels are within recommended range if the engine stalls or runs poorly. Most Polaris ATVs take leaded or unleaded gasoline with a pump octane number of 86 or higher. Engine oil type and amount varies according to make and model.

  • Inspect the condition of the fuel in the tank. If it looks gummy or watery, the fuel may be contaminated. Drain the fuel tank and refuel with fresh gasoline.

  • Check the fuel vent lines leading from the fuel tank to the engine. If either is kinked or broken, replace it with a new one before attempting further operation. Be sure to clean any fuel that may have spilled onto the outside of the ATV using a damp, clean cloth.

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