2004 Polaris Sportsman 500 Reversed Terminals On Battery

[Frank Angerano]

First things first.  Head gasket and or water pump failure.  One or the other.  Then deal with the carburetor/fuel pump issue later.   

 

[JacobSlabach]

Will it hurt it to just let it burn?  If not, I'm probably gonna just sell as is because I'm at my $$$ limit on this bike...

[Frank Angerano]

Yes eventually it will blow out completely and not run any more.  A gasket kit is cheap enough.   The labors a bit of a task but hey you love Polaris!! 

[JacobSlabach]

haha ok well I will get right on that.  another thing-  havnt touched and fluids yet-  I was going to use the Valvoline oil for the engine?  What for the tranny?

[Frank Angerano]

Double check your spec for that.  You never know with Polaris 😂 put the wrong drive train fluid in and the bike may sh** the bed🤣. Just kidding.  

Btw this might be a good time to put the bike  on a bench and tear it down and do things right. Maybe the bushings, gaskets, axle etc.  maybe break it all down and get into slowly but before the summer so it’s ready to go.   Just a thought. 

[JacobSlabach]

ha good one.  I'm thinking the flooding is from bypassing the pump-  It makes since that the gas might be pushing on the needle too hard forcing its way into the carb bowl, bubbling up through the carb and into the intake or airbox(whichever is lowest)  You have to give it to polaris though- only problem its had that I didnt cause so far is the head gasket.  And it still rode perfect once I got it going today-  rode out on the road with a friend and had it pegged for a couple miles on a back country road...  Tons of fun!  wish I coulda video'd it with my go pro-  probably topping 50 most of the time when not sliding around curves- bike didnt give a hiccup and almost popped a wheelie at one point...

[Frank Angerano]

That’s great.  You should invest in a clip for your phone that straps to your chest.   

[JacobSlabach]

one problem.... parents wont let me get a smartphone 😭

[Frank Angerano]

Ahhhhh so how do you manage this forum? Computer ?

[JacobSlabach]

yep got a laptop.  Ok so heres whats going on:

1. Fuel pump hooked back up- no more flooding and it appears to be working
2. It no longer smokes...at all
3. I took the 'snorkel' off the top of the airbox lid and adjusted the carb needle up (richer) to let more fuel and air into the engine
4. The radiator has drained the antifreeze twice so far

Heres my theory:  The 'smoke' was just condensation because it was 40 or below when it was doing that, now that it quit, it over 50...  The antifreeze disappearing:  I guess the radiator was drained or leaks because the bike was sitting for a long time before I got it.  I'm thinking as the radiator runs, it is sucking antifreeze into itself.  I think this because I noticed that there were bubbles coming up from the hose in the antifreeze while the engine was running.  Any input would be great!  If this is what I think it is, the bike is ready to sell as soon as I clean it up....👍

I will say to all those out there with carbureted sportsmans:  If you want more power, Take the snorkel off the airbox lid and adjust the carb needle clip down one notch-  My sportsman is scary responsive now, it roars and also spins the rear tires if pegged.  Before there was about a half-second delay in the throttle to rear end, now they seem to be directly connected- and my belt is shot too

[davefrombc]

The cooling system  should be full  of anti-freeze /water  mix .. there  is an expansion tank  where you  fill the system..  When  the  system  is cold and full  the level  should be at the full  mark  on the expansion tank.. As it  heats up  the  coolant expands and  some is forced into the expansion  tank..  Shut  down and cool off and it  is drawn  back into the radiator..  If  the expansion tank  is too  low  or the  radiator  has been  opened  cold and air allowed in either  by  drawing fro the  too low tank  on cooling , or by opening the rad ,  air will  bubble into the expansion tank  on warming up.  If all  levels are right , there  should be no  air  bubbling into  the expansion tank  after all  the air allowed into the radiator  has  been  released after  one  or two  heat and  cool cycles .. If  bubbling still occurs  after everything is  normal  and cycled a few times , you have a leak  in the system.  Most likely  a head gasket leak.

The  "smoke"  or steam  in the exhaust  is  normal  in cold weather  , especially if it  is wel l below  the temperatures where you see your breath ..  One  on the products of fuel  burning is water vapor. It condenses  in the muffler  when the engine  cools  and is  boiled off as steam  when it heats up. .  If there is a  lot , it could mean  a slightly leaking  head  gasket ..  The main indication of that  is the level  in the expansion tank  going  down  below the add  fairly  quickly  and constant bubbling into the expansion tank.

[JacobSlabach]

ok so I here you saying it could be both a head gasket and condensation?  I did happen to look in the cap of the radiator when I had the bike apart before I got it running and I didnt see anything in it-  I'm thinking its just slowly refilling itself?  Anything I need to do about it?  Fill from the radiator maybe?  And the steam seems like condensations to me- only does it when (like you said) its cold outside and I can see my breath.  So when I turn the engine on from cold, there is a pause (muffler heating up probably).  Then it gushes white for about a minute, then quits for the rest of the ride- till the engine gets cold again.  And doesnt do this when above 40ish

[davefrombc]

Fill  the radiator with  anti-freeze mix and cap it . Afterwards  top up  at the expansion tank. Any air  left in the system  after you've filled the radiator  will  be expelled as the motor  heats up.  Once the radiator  is full  and all  air  from  having opened it to  fill  there should be no  more bubbles coming from the radiator to the expansion tank.  If it continues to  bubble  and  level  goes down  you have a leaky  head gasket.  the  steam in the exhaust  depends on the moisture amount in it ..  In very cold weather it  may  steam  for  a minute or two  before clearing, but if you're  getting a  lot and you see the bubbling and  fluid loss, then  it's  most likely  a  small leak in the head gasket.

 

[JacobSlabach]

Ok thanks!

[JacobSlabach]

update on this bike:  Radiator finally filled up, fuel pump went out (I let dirt get into it when I ran it gravity-fed and it clogged it up or something..)  ordered a new pump ($10).  it still smokes condensation when its cold out, but no sweet smell and no smoke when its about 50.  overall I love this bike, want to sell to get a newer/bigger sportsman.

I still cant get over that it will burn out on asphalt even with a burnt up clutch that doesnt engage till half throttle.... just too much power in this bike.

[Frank Angerano]

You are out of your mind kiddo! Burnouts on asphalt ???? Try not to kill it before you sell it!  

[JacobSlabach]

I'm tellin you man- these bikes got a lot of horse torques

[JacobSlabach]

so I'm trying to figure out if I want to keep this bike or sell it.  So I want an 850 or 1000cc for playing around and work and trail riding and stuff...  but I kinda want to keep this bike and make it into a mud bike...like put bigger wheels on it, snorkel and relocate the radiator...that way if I sink it and kill it, its 2k gone rather than 8k (for a newer efi model)  Yoiu guys think its worth it?  Is this a good bike for modding it into a mud machine?  If so, what necessary and whats not for the mud?

the other option is to sell it...  I know I can get at least 2500 out of it right now..  I have 2k in it currently.

[JacobSlabach]

comment on what you guys think i should do with this bike...  my biggest concern rn is how big can I go with my wheels?  I was thinking of a square setup (front tires are as wide as the rear) with 1in wheel spacers.  I have a 2in lift on the bike, but I concerned that 28in are gonna scrub the fenders...?

[Frank Angerano]

To be sure about rubbing your going to have to collapse the suspension as much as you can then take a measurement form the center of the hub to the fender where the first contact would be. Then measure your potential wheel from center of wheel to edge of tire. 

Maybe a good ratchet strap or a come along to collapse the suspension to mimic how far the suspension will travel but be careful.  

 

[JacobSlabach]

yes was checking that.  looks like the closest fender-to-wheel distance is from the the foot rest to the wheel.  plenty of room above the front wheels, just not behind them.  I was wondering about front a-arms that relocate the wheels forward?  

[JacobSlabach]

so yea i decided to keep it for a mud machine.  Looking to snorkel it eventually- maybe something like this?  Not looking to get the snorkels really high, just want them higher than they are now.

eh sorry those are tiny pics 

and the wheels something like this

[JacobSlabach]

so i guess the main things I'm going to be working on 

1. Need a-arms that relocate the front wheels forward
2. need a snorkel
3. need a radiator relocate...???

not sure about the radiator relocate- I think the main thing would be how low down the coolant reservoir is and it has a breath hole in the top...

was looking at some tires like these:

[JacobSlabach]

and i really really like these but they are 200 each just for the tire- the above pics were off CL for 400 (the blue rimmed set) and 900 (black rimmed set)

[JacobSlabach]

heres a link to the a arms i was looking at- wish they had more of a description...  cant really tell if they would fit or what the specs are lol  https://www.walmart.com/ip/HIGH-LIFTER-Max-Clearance-A-Arm-Kit-Red-309039/613754664?wmlspartner=wlpa&selectedSellerId=6281&adid=22222222227164521103&wl0=&wl1=g&wl2=c&wl3=277941892770&wl4=aud-566049426705:pla-462033282706&wl5=9008704&wl6=&wl7=&wl8=&wl9=pla&wl10=114441983&wl11=online&wl12=613754664&wl13=&veh=sem&gclid=CjwKCAjw5dnmBRACEiwAmMYGORrT-LoKHJUNA5EpLFsy9SyPaDr1uR_r4S9yV6s6rhEOCQuoIc4XYBoC-eAQAvD_BwE

[JacobSlabach]

update on this one- sold it a while back for $3200.  miss it bad but hopefully ill run across a good deal on a 500 again.  fingers crossed

[Frank Angerano]

Dam @JacobSlabach this was a blast from the past post.  
$3200 was a good price for that bike.   

[JacobSlabach]

9 hours ago, Frank Angerano said:

Dam @JacobSlabach this was a blast from the past post.  
$3200 was a good price for that bike.   

yea it was the best flip ive had so far- NADA guide said it was worth $2500 at the time.  guy came said he needed a trail ready bike, i told him this thing wouldn't let him down, he was fine with what i was asking and took it home

what was even better is the bike that took its spot in the shed was the 570 i got now and i picked that one up for $3600 as is- have about $4000 into it now with extras and all