1993 Suzuki King Quad 300 bucks and farts like crazy
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By gbanker
19 miles, 1.7 hours. Gas gauge reads full (WTF???).
South of Tucson, AZ of RT 83. Rosemont OHV trails. 85°, sunny.
Lunch stop where I found some shade.
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By AnthonyT
Does anyone have a digital copy of the service manual they are willing to share I’ve looked all over the place and I can find a free copy. Thanks!!!
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By Ejwill
I put a new carb on my trx500fe which I have done before on other models, but this foreman was a real pain, takes forever to get to the carb. Anyway I got the new one installed . I also changed the choke cable while I had it this far. When I turned the gas back gas started running into the air filter box. I did have trouble with the choke cable, it didn’t seem long enough to run where the old one did and the elbow that came with the new carb had more of a 90 on the angle. It didn’t feel like it was binding but I don’t know if the valve was seated on the valve seat. The choke pushed in smooth but who knows what happened in side the valve body. I don’t know if this could be the problem or not I hadn’t run the it just turned the gas back on. Appreciate any help, hint, hint Mech and GW or anybody else. Deer season is over in a little over a week. My power chair won’t make it down those muddy roads. Thanks again.
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By PolarisRich
I've never done this before but after reading a few thread I decided to check my valves for the first time and to my surprise it was much easier than I thought.
My bike is a 2005 Sp 500 HO.
I first pulled the seat and the right side panel off, and that's it! It wasn't too bad to get at.
Next I pulled the spark plug out and removed both the head cover ( 8-8mm bolts)
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then the side cam cover (5-8mm bolts).
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Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
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Next I turned the engine over with the pull cord untill it was at TDC of the compression stroke.
The best was to tell that your at TDC of the compression stroke is to rotate the engine until the
timing marks are parallel to rocker cover gasket surface.
The cam sprocket locating pin will be facing upward directly in line with the crankshaft to camshaft center line.
Now fine adjust by looking into the timing hole in the recoil cover and line up the upside down "T" on
the flywheel into the center of the hole.
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Now using a feeler gauge, slide the .006" (.15mm)blade between the top of the valve and the bottom of the adjuster and adjust accordingly
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To adjust, Loosen the locknut (10mm) and check clearance with a feeler guage. Clearance should be .006" (.15mm) for both, intake and exhaust valves. Turn the adjuster with a stubby flat blade screwdriver untill the proper clearance is achieved then tighten the locknut (5.8-7.2 ft. lbs) while holding the adjuster in place with the screwdriver. Re-check the clearance with the feeler guage one last time and re-assemble the covers (72 in.lbs) and plugs.
The only thing that i noticed was that I had to clean and silicone the side cam cover other than that I found the whole process rather simple.
I'd give it a 4 out of 10 on the skill level scale.
I hope this helps!
Thanks Rich
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By Sportsman500guy
I bought a 1996 Sportsman 500 4x4 about a month ago, and I love it. Unfortunately, I've been experiencing a few problems with the high-range gear. The first problem is that the gear selector will intermittently pop out of high and into neutral. This problem will sometimes occur when starting from a stop and sometimes will also occur while at cruising speed. The last time this happened I stopped and put it back into gear, however, as soon as I tried to throttle the machine would die. I turned it on again with no problems put it back into high and it died again. Once again I turned it on with no problems put it into low instead and it worked fine with no problem. I drove in low down the road slowly for a little and then shifted back into high with no issues.
I plan on working on it this weekend and would just like some opinions or feedback from anyone who may have experienced these problems before. I'm very mechanically inclined but im unsure of exactly where to start as this is the first Polaris ATV that I've owned. Any feedback is appreciated and thanks in advance
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