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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
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)
then the side cam cover (5-8mm bolts).
Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
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.
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
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!
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?
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I live in Minnesota and bought a 2016 CFORCE 500 HO. I am in hope to see if there is anyone in the US that is experiencing this sudden drop off in RPM below 4000 RPM. I have uploaded some videos of my issue on YouTube. I will list three of the four I posted. The fourth can be found on my channel but it is a comparison between my Polaris 570 and my CFORCE 500.
I quit on my first dealer because we just did not mix well together. I brought it to another CFMOTO dealer that just became a CFMOTO dealer in January 2016. They are in a large ranch and agriculture area in a neighboring state that is pretty close to where I live. They have close to every brand available. They are a much larger dealer than the first one I bought the unit from.
I brought the unit three weeks ago to them and they have worked on it a good solid week and have given up on it. I have read reports from owners in Canada that the dealers there were aware of the issue and have had success in fixing the herky jerky drivability issue.
I am picking it up tomorrow and bringing it back home. It has been to the trails of the Black Hills this year and was new in late April. 300 miles on it. It has never changed. Very hard to ride on the trails or when I herd livestock.
Here are the links to my videos.
I can't accept that this is normal operation. Does anyone from CFMOTO China scan these posts?
I need help that CFMOTO USA has not provided.
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