Answer
Jul 22, 2025 - 09:12 AM
To change the spark plug wire assembly on a 2004 Polaris Sportsman 500 HO, here’s how you do it:
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Remove the seat and side panel – Gives you easier access to the top of the engine.
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Locate the spark plug boot – Follow the wire from the ignition coil to the spark plug.
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Twist and pull the boot off the spark plug – Don’t yank the wire itself; grip the boot to avoid damaging the connection.
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Unclip or unscrew the wire from the ignition coil – Depending on the design, it might be a threaded connector or just a friction fit.
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Install the new wire – Connect one end to the coil securely, then push the boot firmly onto the spark plug until it clicks or feels snug.
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Double-check the routing – Make sure the wire isn’t near any hot surfaces or moving parts.
That’s it. If the wire comes as part of a coil-pack assembly, you’ll have to swap the whole unit, which still mounts with just a few bolts.
If you'd like a more comprehensive procedure, you can check this 👉🏻 2003-2004 Polaris Sportsman 400, 500 H.O. ATVs OEM Service & Repair Manual. It contains the manufacturer's recommended procedures on the spark plug, including step-by-step instructions, clear images, and exploded-view illustrations.
