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2001 Polaris Sportsman 500 4x4 Fire Out Of Exhaust and Intake
By
Chase Cook, in Polaris ATV Forum
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Similar Tagged Content
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By jwline
Friday evening went riding, rode for a good hour or so everything was fine. I went to take a short ride to the restroom (less than 100 yds away) and all of the sudden everything flickered and then just died out. Accompanying the problem I noticed the killswitch completely locked up. Once daylight hit took the killswitch apart to find it had shorted out and melted the plastic inside. Has anyone else had anything similar to this and if so what did you do to fix the situation? I have a new killswitch on the way to replace the obvious problem but was wondering could there be a bigger issue at hand. We tested with a voltage meter to make sure everything was still getting power from the battery and as far as we could tell it was.
Any advice/info would be GREATLY appreciated.
Thanks.
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By bodon
Anyone know what the fuse terminal marked UNSWITCH does . Even with the key off it is causing a drain on my battery and I'm trying to figure out what that terminal goes to. It's a 10 amp fuse. If I pull it the "short" goes away. Thanks in advance.
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By Outkast7222
Had a spark-plug break off, had to pull the head to get it extracted. Where the heck is the timing mark on the crank? Do I need to pull the stator or flywheel to find it? When I pulled the head I had the mark on the cam lined up pretty good but I cant remember if it was perfect and don't want to reassemble a tooth off and have to go back through the bear of pulling this thing back apart.
Thanks guys!
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By Brian Sosebee
I just rebuilt my 03 sportsman 400. Put everything back together added oil per the manual. Pinched off the oil tank vent line 2" away ran for 45 seconds then cut it off. Check oil level and it was still way high so I wasn't confident that it primed so I did it again. Checked again and it's the same. Remove the oil filter and it is dry. I did the procedure again and the same results.
I'm worried to keep trying this as the only oil in the engine is what I used to lubricate the parts when reassembling the piston. The crankcase was drained as well.
I Removed the oil tank and checked all the lines for obstructions and the screen filter and the vent hose and everything is clear. I even pulled a small vacuum on the oil tank while it was pulled off to make sure there were no leaks. The dipstick cap was on tight so I'm not sure why this thing is not priming.
Anyone have any suggestions. I thought about pre-priming the oil lines from the oil tank to the crankcase to hopefully help the system prime. I'd like to be able to add some oil to the crankcase to so I wouldn't feel so bad about running the engine for another 60 seconds without oil. I dropped just a little bit of oil in the spark plug hole to help condition the sleeve right now.
What do I do? Anyone had or heard of an oil pump failure on these. Btw oil pump is working fine before I did the top-end rebuild and the oil pump was not touched.
Please help!!! Thanks all for any and all help.
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By jay rear
Hi im new to the site. I have a 99 sportsman 500. I has been sitting for about a year now. I bought a new battery for it the other day and now i dont have any power to anything but the winch. Any help would be great. I already cut the pouch and checked voltage on both sides of the circuit breaker.
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By Wiley1
Anybody know what the valve clearance is for intake and exhaust on a 2017 sportsman 570? I did a search but it came up with nothing.
Thanks
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By Sha35297
So, I got this 07' Polaris Outlaw 90 in the shop to rebuild top end and transmission. Replaced all bearings and gears in the transmission. Replaced cylinder and piston with brand new parts. Put the engine back on the frame and fired it up. Started great, but had a taping sound in the lower crank case. pulled the flywheel cover off and found the flywheel was wobbling and hitting the stator. I then replaced the stator and flywheel with brand new parts. Timing is all set on the timing marks now, but when I turn it over it kicks back when it fires and ends up stripping the starter idler gear. I've replaced the starter gear once already and now have to replace it again. Is it possible that the timing marks on the flywheel are off or maybe this flywheel is not for this exact model? Thinking of advancing the timing to try it, but don't want to keep going through idler gears.
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By ATVNetwork
news A powerful trail machine ready to tackle the hardest adventures.
Polaris unveiled the 2021 Sportsman 850 Trail Edition ATV with factory-equipped enhancements to tackle the roughest terrain. View the full article
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By NoahJakavi
Hello i have a linhai 300 of the 2004+- era. I had a cluch problem so we changed it. After changing it has a hard time to start going. When you pop it into gear and press the gas it barely drives but when it starts going about 20km/h it start driving well the acceleration is normal and everything do you have any idea of what could be the problem
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By jung4g
The quad has done this off and on, almost since new, but it's gotten worse this year. Sometimes if I freshly charge the battery, it'll work fine, others times that won't matter. Turning the key to on it sounds like it's connecting as I go to the start position, slightly before the full turn, but it's not like there is just a sweet spot to find, it's totally erratic.
Now the battery is basically dead so I put a new, slightly bigger AGM battery in today to replace the factory one with all of 800 miles on it, but those have lots of plowing hours included.
I was able to get it started once, but it still went into limp mode after just a few moments of driving it (that's another topic), so I put it back in the garage and started probing around. Now it doesn't even try to turn over.
Is an ignition switch, the $18 shipped aftermarket variety on Amazon worth a shot? Or should I go straight for the starter? The new switch may not come for over a week, so I hate to just put my hopes in that if I'm missing something obvious. Fuses are good, so it's not something super obvious.
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