Question about Polaris 2006 Sportsman 800 Twin EFI

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The front gear fell off the flywheel on my 2006 Polaris 800 how do I time the marks for the crank sensor

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Arnie Burke

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  • Polaris Master
  • 6,523 Answers

U need a shopmanual. Library has chilton and haynes mechanics books

Posted on Jan 29, 2016

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1 Answer

2005 Polaris 500 will not start even with either , but has a spark ? Need to start testing somewhere?


Check to be sure the Flywheel hasn't slipped on the Crankshaft - Take a look at the Cam Timing marks and make sure they line up at TDC Compression with the T mark on the Flywheel.

Jan 15, 2018 | ATVs

1 Answer

Polaris Sportsman 90 it bogs down/stalls. new carb. it will rev up in neutral. however when you put it in gear bike will only run for a few minutes and then stall or quit running. will restart .


Check the Flywheel key. It should be locked under the pull cord, where the stator is located. I will be a small piece of metal that slides into the spline from the engine and the stator. If it is worn the stator will rotate off the spline and the timing will be off, she won't start and if she does will be really rough and backfire, sputter and have power loss.

Dec 08, 2016 | Polaris 2006 Sportsman 90

1 Answer

2004 polaris ranger


Sounds like the key cylinder contacts is at fault on the normal position. you may be able to jump this for a test.
Maybe also confirm the starter is retracting after it initially engages the flywheel. Sometimes heavy corrosion in the starter prevents this from returning and would stall the engine as the gears stay engaged.

Jun 07, 2016 | Polaris ATV

1 Answer

2006 sportsman 800 twin wont fire at plugs gas burner


If you have no spark , check kill switches for corrosion, does the light work when u turn it over ?

Nov 09, 2015 | Polaris 2006 Sportsman 800 Twin EFI

2 Answers

Starter spins but don't engage and won't start please HELP!!!! This is on a Polaris RZR 800s 2013


Check to see that the pinion gear of the starter is hooting out and engaging the flywheel.
And if it is working it is possible that you have missing tooth/teeth on your flywheel and the starter cannot turn over the engine because of that.

Sep 18, 2015 | Polaris 2011 Ranger RZR 800 S

1 Answer

How do you line timing marks up its out of time


flywheel on T in the compression stroked and cam marks lined up.

May 17, 2015 | Polaris 2011 Sportsman 400 H.O

1 Answer

Battery light keeps blinking on my 2006 polaris sportsman 800 efi


Sounds like you have a dirty ground somewhere. Or it's not charging properly, or can't take a charge because of a faulty battery. Use a dc 12v meter to check the battery.

Sep 08, 2014 | Polaris 2006 Sportsman 800 Twin EFI

1 Answer

Why is the flywheel making a grinding noise when trying to start my polaris outlaw 500?


The starter drive on the starter motor is defective. The teeth on the flywheel could be chewed up too. If you just installed a new starter, you may have to add or subtract clearance spacer metal tabs so that the starter drive engages properly with the flywheel.

Jun 04, 2014 | Polaris 2006 Outlaw 500

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