JacobSlabach

yea I tried putting a cinderblock under the jack and it just tips over--  guess its time to suck up the cost and get a real jack..  You got any suggestions on which kind to get?

I tried...  My jack (dad's jack)  is almost shot and only lifts half way up, and the bike is on a slight incline causing the jack to tip when the wheels come off the ground.

yea... I'm just hoping it doesn't turn into a runaway...  lol

oh i didnt think about that..  I got an old minibike gas tank I could use.  Another thing- its stuck in high.  It seems like the shifter is jammed, so I was hoping that if I got the tranny turning, it would loosen up and shift out of high..  Its gonna be fun trying to feed gas in the engine with a high idle in high with a jammed front axle  🤔👍

thats kinda hard to do since the tank feed is about 4 inches lower than the carb

I took the gas line off the carb and it was almost dry..  I cycled the engine a couple times and nothing changed.  I replaced the fuel filter and still no gas comes out the line (had the fuel valve on the whole time)  I think somethings up with the fuel pump, but the bike started before I screwed up the electrical.

I tried starter fluid in the air filter (just a little cause I know how that can blow the head off an engine lol.....  nothing- but that was with the old sp-  I can try again with the new sp.

I might not be getting any fuel in through the carb because when I took out the sp, it was completely dry.  No blockage in the manifold.  As far as the axle goes, I pretty sure it just popped out (but is still in the boot) because I accidentally dropped the strut on that side when I disconnected the shock.

update:  I got everything back together (had to replace the carb) and this morning went out and turned the key and bam, on pops the display and the needle on the speedometer moved up to 0mph.  Dunno what changed between today and yesterday, but the display pops on every time I turn the key. now I have just two problems.

1. It cranks but refuses to fire.  I checked that the gas was on, checked spark, changed the sp, let it air out, tried again and still nothing.  It was acting like it either wasnt getting fuel, or flooding out.  I know it runs cause I got it started in AL right before I switched the battery terminals.  (The float was busted in the carb causing it to leak so thats why I got a new one.)
2. The back shocks had been replaced with aftermarket longer shocks lifting the back end but nothing was done to the front.  I bought a front end lift kit for it and put it on.  I looks much better now, but the front right axle feels like its binding up when I roll the bike.  The front left side bounces up and down on the shock but the right side is rigged.  I have never worked with axles before so any help on getting the axle in again would be great!

just a 2in lift in the front btw

nothing has power on the pod cluster.  the headlights and taillights work, the starter cranks, I'm not sure yet if the stater works, but I got a new one sitting ready to go in.  I'm planning on trying to start it monday.

the switch appears to be good, the lights and everything works like it should when turned on, and I took the switch itself apart and nothing looked abnormal...no black tips or discolored anything.  

10 hours ago, Rick Shropshire said:

I have 15 posts and it still says Im not permitted to download

its banged up and has cracks in plastics

thats a great looking bike!

hey you too man!  And thanks to the forum and especially you for helping me through this rebuild!!👍👍  It actually turned out better than I expected.

Yea I mean I'm positive its the exhaust rocker that is making the racket.  I would probably want to fix it if I had more time, but I have three atvs now and room for only one..

runs like before, except stronger.  Starts easy with choke, but I still gotta let it idle for a couple seconds to warm up before I hit the throttle or throw it in gear.  I have it up on CL being as I bought the bike to flip (didnt go to well lol).  As far as the clicking goes, my friend (small engines mechanic) said if it was his bike, he would just run it with the tick until something actually broke..  I was planning on selling it as is--  I realize I wont be able to bring as much as if it was spotless...🤔

will do first chance!  and merry xmas to the forum and all members!

I have leaned up close to the engine when its idling and the sound is coming from the upper front corner (exhaust area)

looked all throught the wiring harness, saw neither black bags or those breakers...  I got the new ecm in and now the lights and starter work.  The pod is still not lighting up with the key.

20 hours ago, johniii said:

Ok just watched a video on youtube on the 03 sportsman there are two circuit breakers under the front access panel . Google :How to test circuit breakers on Polaris .

Sent from my SM-G965U using Tapatalk
 

I dont see any circuit breakers.

20 hours ago, johniii said:

Ok just watched a video on youtube on the 03 sportsman there are two circuit breakers under the front access panel . Google :How to test circuit breakers on Polaris .

Sent from my SM-G965U using Tapatalk
 

I dont see any circuit breakers.

timing was never out, even before I rebuilt the bike.  I didnt see any spacers on either rocker when I took the bike apart.  I kept the valves apart from each other and made sure not to mix anything up.  I think the exhaust rocker is just worn...?

ok so I checked the valves and rockers again yesterday.  I believe the exhaust rocker is the cause.  It make a clicking noise when I wiggle it up and down.  I also had my friend (hes worked on many more atvs than I have) over and he said that he thought the rocker had too much play side to side.  I believe that the rocker's clicking when I wiggle it is just magnified when the engine is running.  So I bought this bike to flip it...  I should have sold it long ago before all this happened, but life happens..  The question I have now is should I sell as is or get a new rocker and replace the worn one?  I hate to spend any more on this bike, but if I cant sell it, I'll be forced to anyway..

I'm not sure why the rocker issue would show up now when I wasnt hearing any sounds out of the bike before..  I put the rocker and axle back in just like it came out..  I didnt see any shavings in the head from wear...  I didnt switch the exhaust rocker with the intake rocker.

5 hours ago, Frank Angerano said:

I had this situation happen. The oil fill plug was an allen socket that stripped. So what I did and it may work for you.  First I ordered a new one.  Then I warmed the engine up and had a compound called  “JB weld”. It’s metal repair compound.  I mixed it good and put it in the allen key hole and put the socket into the allen hole as well.  It took 10 min to set up at best so you have to be quick. I let it sit for 15 min and put the socket driver on and spin it out.   

sweeeet fix!

I will check that!  thanks!  and all connections on the handlebars I sprayed with WD40 and made sure they were connected.

btw, having trouble getting the throttle cable unhooked from the carb.  Any suggestions?

1 hour ago, Phil said:

Your doing okay Jacob, I'm still watching this post  to see how you go.

thanks--  I'm just at whits end trying to figure out what could be causing the knocking/tapping/slapping noise on this bike....

On 9/27/2018 at 7:54 AM, brotho said:

My recommendation is start with a smaller quad and get comfortable with it before getting something bigger like a 700cc

lol I learned on a sportsman 500cc 😎  havnt rolled or wrecked yet...been riding them for over three yrs now

On 11/15/2018 at 11:21 AM, lagomu said:

I worked at a Honda dealer in Vero Beach Fl. when they introduced the atc 90. We set the first two up as demos and spent every weekend at Hobart Park (about 2 square miles of sand dunes and a few wooded trails) where we first learned what they would and would not do, then made every effort to instruct customers on what we learned. Some learned and some did not. It was a sad day for me when those who would not or could not learn brought about the end of the 3 wheeler. Quads are far more stable and versatile. They should have been an addition instead of a replacement. Having learned to ride on a 3 wheeler I will always miss them. My advice to any new rider; the biggest safety issue with any machine is the operator, know the limitations (yours and the machines) and last you will never be it's master treat it with respect or it will bite you. Ride safe and never stop learning.

completely agreed.  the biggest safety issue with a machine is the operator!  all the machine does is responds to how your driving it.