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Ajmboy

Polaris 500 Onboard Diagnostics Check

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  • Similar Topics

    • By colin james
      View File 1996-2000 Polaris Sportsman 335/500 Service Manual
      This is the factory service manual for the polaris sportsman 335 & 500.
      You can download the section you need  or download all of the chapters for the complete manual 
      Submitter colin james Submitted 10/19/2018 Category Polaris ATV  
    • 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)
      [ATTACH]1021[/ATTACH]
      then the side cam cover (5-8mm bolts).
      [ATTACH]1023[/ATTACH]
      Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
      [ATTACH]1022[/ATTACH]
      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.
      [ATTACH]1023[/ATTACH]
      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
      [ATTACH]1024[/ATTACH]
      [ATTACH]1025[/ATTACH]
      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





    • By Steven Alter
      I have a 2018 450 and the digital gause has started flashing on an off while driving. The backlit also goes on and off. It is worse when I hit the gas. The battery died a few weeks ago and I jumped it but its been fine until last night. Called the dealer and showed them a vid and they recommend replacing the gauge and its like 600 bucks. The machine has less than 100 hours on it. I would really hate to have to change it out. also the unit sometimes has trouble starting. Any ideas?
    • By Ajmboy
      Here is the Polaris online parts catalog, looks like you need to register with then first. I haven't used it since I'm not a Polaris owner and don't need any parts right now...
      http://parts.polarisind.com/Browse/Browse.asp
    • By Admin
      Looking for Polaris ATV VIN (Vehicle Identification Number) Number Decoders? Once you find your ATV VIN number off the tag on your Polaris ATV, you can go to all kinds of websites that have VIN Decoders available. The best ones are backed by the Polaris ATV manufacturer, however there are plenty of aftermarket Polaris ATV VIN Decoder websites on the web. This topic will stay pinned and if you find any to add, please do it with a reply. 
      The following Polaris ATV VIN Decoder websites are available where you can just enter your VIN number and it will shows you some of your ATV model details:
      KBB.com https://www.kbb.com/vehicle-history-report/ 
      CARFAX https://www.carfax.com
      autoDNA https://www.autodna.com
      VinAudit http://www.vinaudit.com/
      decodeTHIS https://www.decodethis.com
      VINCario https://vindecoder.eu/
      NICB Theft Check https://www.nicb.org/theft_and_fraud_awareness/vincheck 
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      I have a 1999 Sportsman  500, it was running fine, than started to lose power in the winter, I adjusted the idle screw and away I went, than a few weeks ago it died, I have found that i am flooding the engine, compression was at 70PSI and due to the compression release mech. i assume i am good as it compared to the same PSI on a 2000 sportsman 500 i have. i cannot start the atv unless i go full throttle and it starts an runs for about 30 sec than dies, again it is flooded. i ordered a new carb off ebay as i could get one for around $40. put that in same issue, i have checked the timing, (good), valves out of adjustment i adjusted to .006 still same issue, i have found the exhaust lobe and rocker arm to have some wear, i have ordered new ones, but am looking for any other input in this area as well. would the exhaust cam and rocker arm cause the engine to flood? i have used a bore scope and the piston liner has good cross hatching still? any input would be great.
    • By colin james
      View File 1996-2000 Polaris Sportsman 335/500 Service Manual
      This is the factory service manual for the polaris sportsman 335 & 500.
      You can download the section you need  or download all of the chapters for the complete manual 
      Submitter colin james Submitted 10/19/2018 Category Polaris ATV  
    • By colin james
      This is the factory service manual for the polaris sportsman 335 & 500.
      You can download the section you need  or download all of the chapters for the complete manual 
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