Polaris Sportsman Magnum Big Boss 335 400 500 HO 4x4 6x6 Dead Speedometer Odometer Gauge Fix Repair
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- เผยแพร่เมื่อ 20 ม.ค. 2025
- Have a ~1999-2002 Polaris Sportsman/Magnum/Big Boss (probably applies to alot of other models too) with a dead speedometer/gauge unit? They were super common to have this failure, and they are very expensive to replace. When the gauge dies it causes the AWD switch to stop working. It can be bypassed, but it is annoying to not have speed or hours/miles functionality.
Often the failure is a caused by a bad battery, running the ATV without a battery, or a failed voltage regulator. The power transistor used for main power regulation in the speedo unit heats up and fails. In my case, it got so hot it melted the solder and fell out of the PCB. It is a Motorola TIP48 transistor, but can be replaced with almost any power transistor from a power supply.
Information on this fix came from this link, I just filmed my repair:
ka7oei.blogspo...
Hope this helps!
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.
Great! Glad to hear it.
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.
Glad it helped. It isn't too hard to fix!
Same issue and resolved on a ‘99 Sportsman 500. Resoldered same transistor. Works great. Thanks and great video! 👊
Right on! Glad to hear it.
I have a 2000 polaris expedition and had no idea there was even a light for AWD. Now I need to investigate that. Thx
Right on!
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.
Sorry to hear that. Try a different transistor I guess.
Got it. !! There are repair shops to repair Polaris speedometer
Great! I'm sure any qualified repair shop could do this fix.
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 ??
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.
thanks found it
@@norain31 where was the sensor? at the wheel or the transmission? (sportsman 400)
@@M.TTT. it was front right beside brake caliper .
@@norain31 thank you
My speedo works intermittently so Ive decided to replace the speed sensor. Hope that works.
Hope you figure it out!
Success!
These ATV models do not have light bulbs / oil indicators, water charge on board?
No, not in the gauge housing.
@@OctaneElectrons
I asked because I also have the 2008 model and it has no witnesses! Thank you for your answer!
What was the PN for the replacement transistor ?
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.
I want mine repaired not bypass ! But that trick will sure get you fixed
This is a repair, not a bypass. It gets the speedo back to original working condition and AWD switch functionality.
super clean sportsman man
Thanks!
No joke, things is mint.
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 ?
Yes when it breaks it disables the AWD switch that runs through it. It can usually be repaired per this video.
@@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.
Excellent video - thank you very much.
You are welcome!
Mine moves when trying to start it i went through some water than it quite
You would have to disassemble it and see what failed.
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?
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.
@@OctaneElectrons yeah just took off the covering and took out the bulb was burnt out, replaced now works fine thanks!
@@minecrafter4623 Great, glad to hear it!
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
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.
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
What's the difference between the magnums an the sportsmans?
I'm not sure, I've only had Sportsmans.
Do you recall what number mosfet transistor you used?
No, but any common MOSFET power supply transistor should work.
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?
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.
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.
I'll have to look at trans gear shift selector sensor/rotary switch it sounds like from what I read and check the wiring.
Cool I hope you fix it!
@@OctaneElectrons lol, funnily enough, the bulbs had worked and then burnt out, figured it wouldn't be the bulbs, but i was wrong.
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?
Sorry not sure, that year uses a different speedometer I think.
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 👍
Thanks for the info!
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.
Did you have to adjust the speedo needle or just stuck it back at 0mph?
Just stick it back on at 0mph and it will be lined up.
Next level intelligence....!!!
haha thanks.
Great video
Thanks!
You should do a soldering vid!!!
Good idea!
Mine semi works lol. All other lights are working at the moment.
Right on!
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?
Sorry I really don't have time to repair them as a service right now.
Dude awesome video! Would you be willing to attempt to fix mine? No liability and I'll pay you.
Sure, I was considering offering this as a service. Email me at octaneandelectrons@gmail.com to arrange!
Did you send me an email?
My digital parts work
Great!
spedo needle use a fork
Use a fork?
Why on earth would u do that u just wrecked it
Fix the gauge? It worked perfectly after this. It did not work at all before. I don't think you're paying attention...
I have a 2000 polaris expedition and had no idea there was even a light for AWD. Now I need to investigate that. Thx
No problem!