Chase Cook

Yes there torqued to spec. I have an torque wrench to do it with and also the head gasket that was on it is metal so there didn't seem like I had to clean anything. This is the new oem one I just ordered to and just ordered a new head for it to.

It had compression before it started to leak but now it's leaking it doesn't have any. And yes I'm sure its coolant and not gas or condensation. I know this because when first started to fill the radiator up with coolant it would take a long time for it to fill up so a thought there was a problem or it was leaking from somewhere so I heard a leaking noise and it was coming from the front of the motor out of the exhaust port on the top end. And I know the gaskets aren't bad because there brand new and I didn't see any leakage from the head where the head gasket was anywhere.

No unfortunately it does not run.

Have a 2001 polaris sportsman 500 4x4 atv and when I put coolant in the radiator it starts leaking from the exhaust. The valves are sealed but it stopped making compression. Do I need to just replace the head? I just rebuilt the hole top end and this is the only thing +valves that I have not replaced and was wondering if that is why it's not starting up. Need answers please.

I have a Polaris sportsman 500 and I just replace the piston in rings and head gaskets on it and I made sure the timing was exactly right it's getting gas and fire but it still won't start. It sounds like it has low compression but at the same time it sucks in air pretty good from the intake. Also the valves are adjusted to spec. It did start the first time I installed the Piston and Rings but it only stayed running for 5 seconds with starting fluid and then it shut off and then I tried to turn on the next day and it didn't do nothing and I've been going at it for three weekends now and it still ain't doing nothing. I wonder if i set the timing off a little or a lot if it would start up, because I inline the crankshaft sprocket with the crankcase timing line like it said in a manual and the two points on top of the cam sprocket to top dead center of the piston. I even took the spark plug out and stuck a camera light in there to make sure it was top dead center and it still won't do anything. AlsoI drain the carburetor some and shut d fuel petcock off to see if it was getting too much gas and that still isn't the problem. And where I live all the darn mechanics that work on Polaris ATVs are booked for two weeks which sucks and I need hope immediately or I'm just going to set the ATV on fire because I'm getting very frustrated with this crappy brand. Every other name brand ATV I worked on I got it running right and I replace the piston, rings and everything etc, and they started up fine. But this is starting to get very frustrated and I don't know who to talk to who had this problem before, who "don't have to come look at it". Cuz when they say that that means you're not going to come look at it until 2-4 Weeks later because there booked, which I don't have time for. Living in northern part of Florida sucks.

I have a Polaris sportsman 500 and I just replace the piston in rings and head gaskets on it and I made sure the timing was exactly right it's getting gas and fire but it still won't start. It sounds like it has low compression by the same time it sucks then are pretty good from the intake. Also the valves are adjusted to spec. It did start the first time but it only stayed run for 5 seconds with starting fluid and then it shut off and then I tried to turn on the next day and it didn't do nothing and I've been going at first three weekends now and it still ain't doing nothing. I wonder if i set the timing off a little or a lot if it would start up because I inline the crankshaft sprocket with the crankcase timing line like it said in a manual and the two points on top of the cam sprocket to top dead center of the piston. I even took the spark plug out and stuck a camera light in there to make sure it was top dead center. And where I live all the darn mechanics dot work on Polaris ATVs are booked for two weeks which sucks and I need hope immediately or I'm just going to set the ATV on fire because I'm getting very frustrated with this crappy brand. Every other name brand ATV I worked on I got it running right and I replace the piston, rings and everything and they started up fine. But this is starting to get very frustrated and I don't know who to talk to who had this problem before, who "don't have to come look at it". Cuz when they say that that means you're not going to come look at it until 2-4 Weeks later which I don't have time for.

5 hours ago, Chase Cook said:

 

The timing is not a 180 degrees out. I made sure every single thing was aligned and timing was lined up right. Now it wants to suck air like it's supposed to but you and fire out the exhaust now. I mean when that happens I know it's getting gas. but I'm trying to figure out if it's something to do with the rocker arms to. Because there's one in the middle that goes into a V shape to the exhaust valve and there's two rocker arms on each side of that one that hooks up to the intake valves. Because that one that goes into a V shape, I'm trying to figure out if the valves have to be adjusted the same exact spec because they both go down at the same time. 

The flywheel key looks brand new. I just talked to someone and they said the timing is probably incorrect still. Because they said if the intake valve is open and it's making spark at the same time lol shoot out the intake/ carb and of the exhaust valves is opening at the wrong time while it's making spark it can do the same with the exhaust. So I guess I have to keep on somehow addressed in the timing for the fire right.but I looked at my owner's manual and there's two dots on the cam the line to line the cam up and and that's how I did it but it's still doing the same thing. So I guess I have to adjust one tooth out of time LOL which will take forever. But he also said that it could be a hundred eighty degrees out so I'm trying to figure out if I have to make the cam lobes facing upwards then instead of downwords then.

Okay I just got everything back together and I made sure to crank timing in the can timing is aligned and everything else and I put everything back together like it is and I started it and it still shooting flames out the exhaust. I don't know what the problem could be at this point. The ignition timing is right.

Just now, Chase Cook said:

Okay I just got everything back together and I made sure to crank timing in the can timing is aligned and everything else and I put everything back together like it is and I started it and it still shooting flames out the exhaust. I don't know what the problem could be at this point. The ignition timing is right.

Unless the ignition timing isn't right? Its aligned with the top end.

The valves are fine. I think I know what the issue is now. There might be a timing mark on the crank itself to and it's not aligned with the top cam. Because I just change the teeth over a couple of times now and now it's sucking from the exhaust and shooting air from the intake. So I think it's just a timing issue now.

Not anymore it doesn't. That is what I was talking about.it started to lose power when it was running and I was going down the road with it.It made a poof noise and started to lose power. It did start and idle before all of this happened. But now it doesn't want to start.

Hi I just got an Polaris sportsman 500 4x4 ATV the other day. I got it real cheap but I started to go into it because it didn't have compression so I bought a new piston and ring kit for it and installed it, but now when I try to start it all it does is shoot fire out the exhaust or the intake of the carburetor. And a timing is top dead center.;I think I can't really tell another way if it is or not. when I put it together I made sure to piston was on top and the cam lobes where facing down where are the cam sprocket is facing up. It has gas and spark. It did start a couple minutes ago but it didn't stay running and now it won't start. Do you think the valve need to be adjusted more to close better?I'm fixing to try that out and if that don't work what is the problem? Also I made sure everything was together good and right and change the oil and changed out the radiator fluid.

Hi I was riding my Honda the other day and I gave it gas for about a quarter-mile just flooring it and then it started to lose power. I pushed it about a mile home which was a pain in the butt but when I got home It still had gas, compression and spark. Do you think the timing jumped possibly?

Also I was going to ask you what kind of transmission is this. a 5-speed or 4-speed. I heard that if it's a type 2 Honda that the five speed will fit the 4 speed. Mine's a 91 so it's the year lower then when they started to make the five speeds witch suck. And if this is a 5 speed I'm going to buy it so I can put it in mine.

Hey Frank, I got ATV running. Its running like a top now LOL.

Also I was going to ask you what kind of transmission is this. a 5-speed or 4-speed. I heard that if it's a type 2 Honda that the five speed will fit the 4 speed. Mine's a 91 so it's the year lower then when they started to make the five speeds witch suck. And if this is a 5 speed I'm going to buy it so I can put it in mine.

Thanks for your support Frank. I will let you know now that I just put the topping on and it fits perfectly. The only thing I have to do now is put a new spark plug coil on, and I ordered a CDI because it is a sparking now. I replace the stator and rectifier and I did it tester and they both have ohms but I'm thinking now it could be to CDI going out. And also I have to tighten the top of the valve cover down and get everything situated to try to start it. It will probably be another two weekends before it's fully ready. But tomorrow and Saturday hopefully I can get all situated and started.I just got the whole top end and cylinder kit today and other things for it. I'm going to put on. Of course I already put the cylinder kit when there though.I'll send you some pics probably tomorrow or Saturday.I didn't get a chance to take them today because it's getting late and I have to work early tomorrow. But keep y'all updated. Hopefully I can send a video to.literally the only thing that I'm waiting for her to come in as a new muffler but it's going to be June before it comes in LOL. And I bought of course like I said another CDI box which was $50. And I also bought the clutch kit for it because when I first road it,you'd have to floor it for a couple seconds for it to kick in and start going. So I'm thinking the clutch is slipping but it was about $50 for that too.so I'm probably $1600 into it now Lol. But my battery went shot so I'm going to have to go and get another one which is another almost $50 LOL. But I'll let you know and let y'all go now.

Okay thanks markinAR, when these wear out I'll get me probably a set of trailer tires to put on there. I saw some good ones but they were a little bit too pricey for the rims too but now I can just buy the tires and they'll be cheaper.

I was thinking about you buying a used cylinder because there was one for about that much or it was like $100 or $120 but I didn't know if I should have trusted it or not so I just went ahead and just bought a brand new kit.also their golf cart tires but I'm going to be running out on the street a lot so hopefully they will work well on the street. if not I have some good size rims on there now I can put street tires on when they wear out.

Okay I honed it out and it's still not fitting.it's fitting only a quarter way through the top and the bottom but when you push it through the middle it almost gets stuck without the rings in it. And I heard the living crap out of it and it still ain't working.Well I'm thinking of is the whole cylinder is warped and you definitely have to board out if that's the case so I just bought a whole new cylinder head and piston kit. It was pretty expensive $375 but it should be here tomorrow but I'm not sure if it will be done by tomorrow this weekend I will have it on and hopefully get it running.I am fixing to send some pics so far of what I done to it.like the tires LOL because I don't have no more pics of the rest of the stuff. Definitely not finished with the plastics and all that though and tires. I still have to drill 2 more tires out for the studs to fit but the other two I did just right and they don't wobble but I think it looks good so far. It was kind of dumb but I put about now $1,500 in the ATV so when I get it running it should run like a damn top LOL. Hopefully I can get about 1500 to 2000 out of it.

Ok thanks. I'll try that out.

Yes I just bought a micrometer the other day in the other piston that was in there is a 65 mm and I just checked the new one to make sure it's 65mm and it is. I was thinking possibly that they did put a smaller cylinder in there but it's the same. I'm thinking that I have to get a 64 mm piston which they do not make them for this ATV since 65 mm piston is standard OEM

Yes it's the right CC.

Also I replaced pistons and at least six of the vehicles I had over the last few years and never had this problem

1991 Honda trx200d type 2 ATV.

Now I have almost all my parts in. Still have stuff on its way, the rear hubs,  rims and tires, fuel petcock, (Another) battery, front wheel bearings, front brake pads, fuel line, muffler, coil, and miniature dash. And a plastics paint job.

Only problem is now is to that I bought a brand new top end kit. OEM 65mm piston kit, and it was a pain in the as* to put through the cylinder sleeve for some reason and now it barely wants to turn over, because I might of forced the Piston and Rings in it. But I still don't know why it was so hard to put them in? And was wondering if I need to get a new cylinder sleeve/ hole head for it or not. Or take it somewhere to get the cylinder sleeve bored out a millimeter or two so it spins more freely?

I'll update you when I get it running.

They should be. there from tusk.