Polaris Sportsman Magnum Big Boss 335 400 500 HO 4x4 6x6 Dead Speedometer Odometer Gauge Fix Repair

[@SammyD1997]

Thank you, this video helped me diagnose my 2000 magnum 500 awd issues I haven’t fixed the speedo yet but I jumped the two brown wires to confirm that all of the rest of the awd system works. Going to take my Speedo apart later to try to fix it.

[@OctaneElectrons]

Great! Glad to hear it.

[@garagecraze]

Thank you for the video. I took mine apart today and it was the exact same problem as yours. That same part just fell right out of mine. Now I have to learn how to solder a new one back in there without wrecking the entire thing.

[@OctaneElectrons]

Glad it helped. It isn't too hard to fix!

[@sstreet3461]

Same issue and resolved on a ‘99 Sportsman 500. Resoldered same transistor. Works great. Thanks and great video! 👊

[@OctaneElectrons]

Right on! Glad to hear it.

[@truenorthmuskoka9077]

I have a 2000 polaris expedition and had no idea there was even a light for AWD. Now I need to investigate that. Thx

[@OctaneElectrons]

No problem!

[@chris1448]

Great video! I wish we could see the soldering part though. My speedo wasn't working, took it apart and the transistor had fallen off. Tried my best to solder a new one in, but it didn't work when I plugged it in. Not sure why as there didn't seem to be other damage to the board.

[@OctaneElectrons]

Sorry to hear that. Try a different transistor I guess.

[@peanutbutter2597]

Got it. !! There are repair shops to repair Polaris speedometer

[@OctaneElectrons]

Great! I'm sure any qualified repair shop could do this fix.

[@peanutbutter2597]

I want mine repaired not bypass ! But that trick will sure get you fixed

[@OctaneElectrons]

This is a repair, not a bypass. It gets the speedo back to original working condition and AWD switch functionality.

[@norain31]

Good job , id maybe use my door panel v tool for needle removal .but was wondering everything works on my atv works exsept the needle stopped moving is there a speed sensor on the machine ?? could that have failed ??

[@OctaneElectrons]

The needle came off easily with no damage, no need for another tool on mine, but some might need it. There is a speed sensor on the front right wheel I think. You could check that.

[@norain31]

thanks found it

[@M.TTT.]

@@norain31 where was the sensor? at the wheel or the transmission? (sportsman 400)

[@norain31]

@@M.TTT. it was front right beside brake caliper .

[@M.TTT.]

@@norain31 thank you

[@VASailpwr]

Same problem here. When I bought mine, all the bulbs were blown along with the speedo and awd. Did you figure out what caused the issue with the voltage?

[@OctaneElectrons]

It could have been the voltage regulator on the ATV, but it did seem to be working. I think the power transistors just fail inside the headlight unit on their own sometimes.

[@0001070181]

Hey man, I have a 2004 magnum 330 4x4. The speedometer doesn't work & my awd selection doesn't work. but the gear read out, and hours work. Do you think this is the same issue?

[@OctaneElectrons]

Sorry not sure, that year uses a different speedometer I think.

[@stefandedu20]

These ATV models do not have light bulbs / oil indicators, water charge on board?

[@OctaneElectrons]

No, not in the gauge housing.

[@stefandedu20]

@@OctaneElectrons I asked because I also have the 2008 model and it has no witnesses! Thank you for your answer!

[@moneyhauler1]

Did you have to adjust the speedo needle or just stuck it back at 0mph?

[@OctaneElectrons]

Just stick it back on at 0mph and it will be lined up.

[@gdunavant2011]

Hey i got a 98 polaris sportsman 500 looks just like yours but 98 an my speedo dont wrk no lights needle doesnt move an odometer dont wrk i took my speedo apart an both transisters are still intact, do u think it could b bad? An my 4wd wrks tho too

[@OctaneElectrons]

Sorry not sure. I haven't seen that combination of issues where everything is dead on the gauge but transister is good. Your 4WD might be working because somebody already did the bypass mod.

[@gdunavant2011]

I found out someone put the bypass on for the 4x4 to wrk , an it’s a great video u have here , now I’m just wondering where do I find the tip 48 transistor? Thanks

[@brianpringle4763]

What was the PN for the replacement transistor ?

[@OctaneElectrons]

I believe it is in the video? If not, any power transistor of the same type I show will work. Not real picky about it.

[@M.TTT.]

Have a 2002 or 2004 Polaris Sportsman 400 I am trying to fix for my dad --- I need to go look at it, I think the speedo would light up, but there were no shift indicator lights or speedo reading (or the speedo was random), I will have to see if the AWD lights up like yours also. I may send ya an email if I do open up the speedometer and can't get the transistor soldered on if it is needed. I think I may have a more in depth wiring issue due to the previous owner though unfortunately and this thing has a poorly written wiring diagram/owners manual.

[@M.TTT.]

I'll have to look at trans gear shift selector sensor/rotary switch it sounds like from what I read and check the wiring.

[@OctaneElectrons]

Cool I hope you fix it!

[@M.TTT.]

@@OctaneElectrons lol, funnily enough, the bulbs had worked and then burnt out, figured it wouldn't be the bulbs, but i was wrong.

[@TheTechGuider]

super clean sportsman man

[@OctaneElectrons]

Thanks!

[@Erix7810]

No joke, things is mint.

[@peanutbutter2597]

So the problem with the 4 wheel drive is the speedometer ? Is there a place where I can send it to so that it can be repaired ?

[@OctaneElectrons]

Yes when it breaks it disables the AWD switch that runs through it. It can usually be repaired per this video.

[@mattevans491]

@@OctaneElectrons The AWD still works though doesn't it? Mine was out last summer before a trip to Tennessee, but I didn't notice the AWD not working. I didn't notice the light not working either, but it's hard to see. I guess I should check to be sure.

[@lessurette4772]

Original part is a tip48, npn transistor. I would try and get that part or a suitable replacement. Mine was not melted out but shorted in circuit. Edited to be more positive 👍

[@OctaneElectrons]

Thanks for the info!

[@dvcm27]

Do you know what the large capacitor (qty 2) part number that sits in front of the tip48 npn transistor? On mine, both are fried.

[@minecrafter4623]

What about the top cluster headlight? That’s the only thing not working for me. The lower headlights all work fine, but once I flip it to high the top light won’t come on and the lower lights shut off. Would that be a wiring issue?

[@OctaneElectrons]

Well the low beam is the 2 outboard lights on the front bumper, and high beam is the light in the gauge cluster. I would start by checking the bulb in there. Otherwise, yes it could be a wiring issue, or the handlebar switch.

[@minecrafter4623]

@@OctaneElectrons yeah just took off the covering and took out the bulb was burnt out, replaced now works fine thanks!

[@OctaneElectrons]

@@minecrafter4623 Great, glad to hear it!

[@MichaelGordon-i5g]

I'll send you my speedo and you can have at it. My lights work, shows hours/miles AND I can go in reverse using the limiter successfully. I assume I've got some resistor dead? Let me know of your "service" fee?

[@OctaneElectrons]

Sorry I really don't have time to repair them as a service right now.

[@th3duke1]

Excellent video - thank you very much.

[@OctaneElectrons]

You are welcome!

[@skeley1]

Do you recall what number mosfet transistor you used?

[@OctaneElectrons]

No, but any common MOSFET power supply transistor should work.

[@truenorthmuskoka9077]

My speedo works intermittently so Ive decided to replace the speed sensor. Hope that works.

[@OctaneElectrons]

Hope you figure it out!

[@truenorthmuskoka9077]

Success!

[@ambermosier3175]

Next level intelligence....!!!

[@OctaneElectrons]

haha thanks.

[@DJ-zv3rr]

What's the difference between the magnums an the sportsmans?

[@OctaneElectrons]

I'm not sure, I've only had Sportsmans.

[@gabegiguere3964]

Great video

[@OctaneElectrons]

Thanks!

[@jerryullrich380]

Mine moves when trying to start it i went through some water than it quite

[@OctaneElectrons]

You would have to disassemble it and see what failed.

[@ambermosier3175]

You should do a soldering vid!!!

[@OctaneElectrons]

Good idea!

[@excellenceinanimation960]

Mine semi works lol. All other lights are working at the moment.

[@OctaneElectrons]

Right on!

[@bigjoe5659]

Dude awesome video! Would you be willing to attempt to fix mine? No liability and I'll pay you.

[@EvanGrist]

Sure, I was considering offering this as a service. Email me at [e-mail] to arrange!

[@OctaneElectrons]

Did you send me an email?

[@jerryullrich380]

My digital parts work

[@OctaneElectrons]

Great!

[@jimmachen5095]

spedo needle use a fork

[@OctaneElectrons]

Use a fork?

[@eagleflight7501]

Why on earth would u do that u just wrecked it

[@OctaneElectrons]

Fix the gauge? It worked perfectly after this. It did not work at all before. I don't think you're paying attention...

[@truenorthmuskoka9077]

I have a 2000 polaris expedition and had no idea there was even a light for AWD. Now I need to investigate that. Thx

[@OctaneElectrons]

Right on!