Gwbarm

It looks like a fairly nice quad, very capable, but i have never seen one.

I was just reading about it, sounds like a great machine, good luck getting it going. QUADRUNNER LT-F500FY The LT-F500F has been designed as a heavy-duty fulltime four-wheel-drive machine capable of pulling heavy loads, but agile enough to maneuver through tight terrain and fit in a standard size pickup truck. For 2000, the F500F has upgraded suspension with more wheel travel, increased ground clearance, 30mm longer wheelbase and new graphics. The 493cc, liquid cooled engine is tuned for high torque at low rpm, with power transferred through a 5-speed transmission with an automatic clutch and a 2-speed sub-transmission, plus a reverse gear. A unique torque-sensing limited-slip front differential provides fulltime 4-wheel drive traction. The LT-F500F’s frame is made of large diameter, thin-walled tubing and is supported by an independent double A-arm front suspension and 4-link rear suspension with a preload adjustable shock absorber at each wheel. Large, 25 inch front and rear tires mounted on cast aluminum wheels provide ample traction and a smooth ride. Hydraulic front disc brakes and a sealed drum rear brake are standard equipment. Other features include a 325 watt charging capacity, dual 12V DC accessory outlets, twin headlights and taillights, large racks and storage compartment, speedometer and fuel gauge, and a high towing/carrying capacity. Suggested Retail: $6,299

When you take the side cover next to the shifter you should see stator in the case, on the engine the flywheel and pickup coil along with the shifter mechanism, hopefully its in better shape than mine was, although i wasnt having shifter problems. It had just sat with water in it for a while. Check to make sure the shift drum is rotating freely and the spring is attached and doing its job. outback vs cx50

If its a 400 it will be 2000 or newer. All Big Bears are foot shift and most are full time 4 wheel drive.

I am not familiar with that one, thanks for the manual.

In the quadrunner model # you supplied the first F means footshift and the second F means four wheel drive. So if yours is the LT-F500F it should be fourwheel drive with a footshifter. What year is it ? My quadrunner is an Eiger with model of LT-F400F, i know there made a Vinson 500s they may be different. I know its difficult to diffferentiate models they all say Quadrunner on them.

That sounds like a ggod plan,

The welder will work better for replacing missing pieces. Harbour freight bucket, great idea.

I have used numerous different glues and techniques to restore plastics. It can be melted back together, they make a plastic welder that actually uses a curved wire and melts into the plastic to hold it back together, then you can go over it with epoxy colored to the existing plastic to repair. Or bondo if you are going to paint it. Fiberglass can be used, messy, with a colored top coat to match. If its not a very bad crack i have used E-6000 it is a very flexable glue that does a fairly descent job. I have also used Epoxy made to finish Granite countertops, but it dries kind of brittle and would probably break if it was rolled over or hit a tree.

Im sorry to hear that i would have thought Polaris would have better quality controls than that.

I was fairly sure you had already done that, just thought i would mention it. Im trying to think of other options, but Mech has covered all the ones i can think of.

When the power fails do you still have 12 v at your battery, you may need to load test your battery, it may show 12v on the battery but when a load is put on it, like the lights and starter it cant handle it. Also the Big Bear is fairly specific about the battery, it. needs what they say it needs, i put a weaker Amp Hr battery on mine when i first got it and it didnt like it one bit.

I am going through all the electrical componets in my head trying to figure out what might be causing this. You have 2 relays one is for the fan motor, not to concerned about it at this point, then you have the starter cutout relay ,which if went bad would cause it not to start from the start button. You have the soloenoid that hooks directly to the battery, do you have voltage at that post on the soloenoid, but get nothing when you press the start button. I have seen a bad starter do what is happening to you, it may work, but pulling to much amps from a bad connection either externally or internally, check the terminal where the soloenoid connects to the starter and make sure that terminal is solid with a good connection.

If its been sitting for a while the rings may be stuck, it may come around a little the more you run it but if its smoking as much as you say its provbably a badly worn engine. Is it smoking from around the head.

Thats normal, when you press the start button it sends power to the plugin and activates the soloenoid to send power to the starter. So if its starting when you press the start button all that is good. My expierience with bad CDI is they either work or dont work, and it sounds like yours is working, and i dont think a bad CDI would cause you to loose power everywhere just wouldnt spark or start. The only thing i can think of to cause you to loose all power is the main fuse or a bad ground. I keep thinking it could still be something in the stator pickup coil assembly causing intermittant spark but that also should not cause you to loose all power just wouldnt run .

Another thought, you might find another quad that needs work cheaper than a frame, when i was looking on ebay they wanted more for a frame than i paid for my whole Big Bear, but i did have to rewire it and do a few other things. Straitening it would be the cheapest option. My philosophy is if it can be bent it can be bent back.

Not sure which vacum line you are referring to vacum line off the carb or off the engine, if its off the carb it may be there for a vacum petcock and yours may not have that but the carb fits many different models. For checking the valve lash remove the valve cover, turn the engine over until both rockers are loose, use a feeler gauge to check the clearance have looked at your manual but should be intake 002 and exhaust 004 or somewhere in that range.

Thanks! I have not seen it in a syringe, thats would be good, i will look for that. What i get comes in a little squeeze bottle about 2 inches long.

I was thinking there should be one under the drain screw #14, but none shown on the diagram.

Thanks Mech! I need to get some so i will look for 518, i think thats what i have been using , but i will have to double check.

I must have missed something, you cleaned the carb, you tilted it to reinstall on the quad, there shouldnt be any gas in it at this point. So is it leaking at all these places after it is installed and in the correct position.

I agree Loctite is the best, been using in for 20+ years. Although i cannot find the Master Gasket loctite locally that you mentioned Mech, maybe its just packing differences. The same number it just doesnt say master gasket on the package.

A good find indeed, sounds like its an easy fix once you get it up and running so you can see what its doing, stored inside is a big plus!👍

I think i would try that first, its a big job swapping frames.

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