Polaris 500 sportsman give it gas stalls

[Frank Angerano]

Wow and it’s the same shape as the decompression lobe too. Something was not put back right would be my guess because even with the spring off or bad that part should still stay seated.   

Whats your thoughts ? 

[BuggyMasters]

What preceded this? Did it by chance backfire?

[Flipper Tiffany Roper Jones]

Since the spring didn't hold it very tight from it slapping back and forth in there it's only aluminum cans still turning so it got beat by the stop pin and the rod its mounted on flipped sideways and busted out. Theres literally nothing in there but it u no. I'm just glad it busted out not in.

[Frank Angerano]

Yep I think  you dodged a bullet.  So now what ? Have you located a new cap and what’s your thoughts on the cam assembly? Maybe a whole new set up, cam and all? 

[Flipper Tiffany Roper Jones]

Yea I have a spare I bought cycles r us biggest indoor parts yard is 15 min from me so theres my cap I'll let you know how it goes 

[Frank Angerano]

Ok brother. Good luck I’m really hoping this works out, you have a lot of time invested with this machine. 

 

 

[Flipper Tiffany Roper Jones]

Yea no kidding definitely one of the more difficult ones I've had to work on. What happened to just air fuel and spark for god sakes. Now they have all this un needed bs to em now its unreal.

But for $300 in mint condition I'll put in the wrench time every time. 

[Frank Angerano]

Me too! 

[Flipper Tiffany Roper Jones]

I just put in a brand new cam and a brand new cap and it just did the same exact thing is there something that holds that cam or decompression ring in place. Also I noticed another thing when I started it disconnected the battery ran like it was supposed to hook battery back up couldn't hit the gas again. I'm getting so frustrated with thing its unreal about the hundredth time I've taken it apart.

[Flipper Tiffany Roper Jones]

What on earth would cause this 

[Frank Angerano]

Holy crap a second failure!!!! Ok time to take a breather and really look into this to see what’s happening.  That is a serious failure. 

Without disturbing too much try to open the head up see what’s loose or does not look right.   It’s almost as if the engine is kicking backward ? 

[Flipper Tiffany Roper Jones]

It's all open I opened it back up and took the cam out is there anything to holds the cam still 

[BuggyMasters]

Seems to me the timing gear side is what keeps it from walking. On the decompressor side, can the swing weights be put on backwards? I don’t have one here to remember how they are set up.

[Flipper Tiffany Roper Jones]

It will go in 2 different ways but I put it in exactly how the service manual showed it both times now before I put it in and wounded the spring once never had this problem now manual says put it in with spring in relaxed position do not wind it once it will not work right but both times broke the case out like something is throwing it out the busting the weight off and weird thing it started running perfectly when I unhooked the battery its getting so much juice from stator it blew my neutral light out this is crazy I just keep throwing money at it and just keeps costing me more its insane 

[Frank Angerano]

If it’s over charging then the regulator/rectifier is no good.   

[Flipper Tiffany Roper Jones]

Its brand new 

[Frank Angerano]

I hear you but that’s the function of a regulator I’m sure you know that already but maybe it’s defective? Was it an oem or aftermarket? 

[Flipper Tiffany Roper Jones]

OEM but guess it could always be bad I'll order another one.  Idea on decompression 

[Frank Angerano]

No im lost with this. I will keep looking  into it.  Just got back from a long weekend. I will talk to a buddy of mine who specializes in Polaris. 

[Flipper Tiffany Roper Jones]

Ok thanks I'm having the worst luck with this one I usually I don't have any trouble fixing these this ones kicking my ace

[Frank Angerano]

It happens. We all (is flippers) get that occasional machine that does this to us. Best part is when it’s figured out and running good it’s worth the work.  So walk away and do some research and between you and Quadcrazy there will be a logical answer.  

[colin james]

Is the flywheel keyway intatact?. If the keyway is broken can also get an erratic voltage which can  take out the regulator/rectifier. Also can cause issues with timing and cam walk.  My manual state a 1/4 preload on the spring and that the cover is also a cam thrust plate

[Flipper Tiffany Roper Jones]

Key is 100% in tacked. But for some reason its either flapping around in there with enough force to bust it off its steam. Or something is throwing it out so hard to but it off the steam. I just have to believe its bouncing around with so much force to break it off 

[Frank Angerano]

Any luck ?

[Flipper Tiffany Roper Jones]

I went and got a new cam yesterday it doesn't even come with the spring preloaded which sucks. Right now I'm trying to find a cap before I can try it again. Just worried to break another one 

Also ? How on earth can the motor go backwards some where on hear someone said sounds like the motor went backwards how can that happen 

[Frank Angerano]

That can happen if the engine backfires. Usually if timing is off or an unusual amount of fuel that builds up in the cylinder.   The engine kicks back.  

Can you screen shot the page that explains the cam and spring installation and post it here ? I want to read it. I don’t have time to start looking for the manual. 

[Flipper Tiffany Roper Jones]

Yup

[Flipper Tiffany Roper Jones]

[Flipper Tiffany Roper Jones]

Any advice would be awesome before I break another one 

[colin james]

I have the factory manual if you need it