Polaris Sportsman 500. Loss of Power at full throttle.

[@smallgaragehustle]

Having done the aftermarket camshafts, my advice is to stay away from them unless you want to redo the job again. The one I installed ran great, but the decompression ball valve was undersized. This caused the machine to have no decompression at all and be a pain to start electrically and impossible to manually start.

[@TitaniummanGarage]

That's the problem I had as well. Now you guy know why I use used ones. Never had an issue.

[@TitaniummanGarage]

Thanks for your input.

[@Shoots-A-Stick79]

You make it look so easy. Thanks!

[@TitaniummanGarage]

I've probably done over a 100 rebuilds. I've gotten pretty quick at it. Actually, it is pretty easy once you know what to look for.

[@CarlosGonzales-xk5jk]

Can you send me a picture on what wires go were on a polaris sportsman 500 4x4. In need thanks in advance...wiring needed..

[@kennyphillips8603]

Ha!! 1st poster! Yeah buddy

[@user-lv1mh2ur2r]

Hello friend, can you tell me I have a problem with a Polaris 800

[@SwormCycles]

I'm working on a guys 2000 Sportsman 500 right now. Just did a full rebuild kit on the carb (not a Chinese kit) ran the carb through my sonic tank, buttoned everything back up and it started right up (which it was not doing very well to begin with) but like in so many instances, fixing one issue brings another to the surface. It revs up great under no load, but while riding, if I give it throttle much over half way, it bogs out. I first thought it was electrical like in some other vid's you have, but this video I think nailed what is going on with this guys unit. Question is now where to find a cam and rocker set up of any decent quality. I've not done this job on these machines yet so will be looking at some of your other vids on doing so. Thanks for saving me some diagnosis time.

[@TitaniummanGarage]

I buy used ones on ebay. I've heard good and bad about aftermarket.

[@shadedevold5440]

The factory cams have small oiling holes! After market cams have bigger ones! There upgraded

[@TitaniummanGarage]

Nice! Thanks for the info.

[@jasoncarthew2279]

Did the engine has a ticking/tapping sound with the worn lobes

[@levimc6783]

I think the old 400 and two stroke are the best bikes polaris made I had 3 500 and 2 400 I found the 400 last longer and never have a prob with them my 2004 400 has 11000 km and does not use any oil and no clunks or rattles

[@TitaniummanGarage]

It boils down to how well it was maintained. I've seen a lot of 2 strokes blow a top end because of lean conditions or overheating. Then you have to rebuild the whole engine. The bottom ends on the 500's last a long time. But there is the chain and the valves that rattle. I agree on that part. for me. I can rebuild a 500 under 250 bucks. A 2 stroke 400? 4 to 600. Crank bearings, seals, counterbalancers wear out, oiler sticks. But they are so fun to drive. I had 5 of them.

[@levimc6783]

​@@TitaniummanGaragemy 250s got 7500 km on the one and 6200 on the other and did 3 top end jobs since new not to bad all of my 3 500s had top ends jobs to becus the base gaskets whent

[@levimc6783]

The 400 are four strokes the best engine polaris made in my opinion got 11000. Km on my old 400 and runs like the day out of the show case

[@chrislegare1940]

Hey, long time subscriber. I have a sportsman 500 h.o 2003 that has top speed loss. Revs fine but cant seem to get it over 40mph. Ive had both clutches looked at. Has 160 main wich helped and 42.5 pilot. When my secondary wore out i replaced it with a 2008 500 efi roller clutch. I did this because i had gotten a deal on a clutch kit for a 2008 500 efi. Still couldnt figure it out so i got both clutches rebuilt with new bushings. I have 26 inch mudlites on it and the clutch kit is for 27/28s. My last options are taking clutch kit out or replace motor mounts causing belt deflectiion to be off?

[@TitaniummanGarage]

If it's not the cam, It may be that secondary you bought. In neutral will the secondary spread out like it should? I have a feeling that's your issue.

[@kriswalker8296]

Love your videos they help a lot speaking of parts would you have a cv axle for a 94 4x4 front left part 1380075

[@TitaniummanGarage]

Nothing that old.

[@SCOOBASTEVE540]

Man I am seriously chasing a endless issue. My 97 500 runs better than it should if it’s straight off the carb, but if I connect any of the filter housing it won’t go past 1/4 throttle. I am stumped. I’m willing to pay for trouble shooting at this point. (Dealer said idk and threw their hands in the air)

[@TitaniummanGarage]

Dealers don't know shit about these old models. If they can't plug it in to a computer, they are lost. LOL. Once the airbox is on it's cutting down the airflow to the carb. You could try a couple things. Buy a cheap aftemarket carb. See if anything changes. Make sure you clean your carb really good. It could be a plugged jet. Make sure foam from the gas tank isn't blocking the snorkel from airbox. Check to make sure your choke is moving free. It might need adjustment. And check the fuel mixture screw at the bottom of the carb. Also check your breather hoses going to the oil reservoir . If they are pinched off or old..Including the filter on the left side to airbox it will cause issues. I had a 99 magnum 500 with the same issues. Sometimes it doesn't matter how many times you clean the carb, it just won't get clean enough. Also check your carb intake boot for cracks. And last but least check your timing, valve lash ect...Carb is vacuum operated. Make sure your fuel pump is working properly too. Hope that helps.

[@SCOOBASTEVE540]

@@TitaniummanGarage new carb, everything is set well, new timing chain, new cam, new filters. Tried different jets & mixtures. All the same results. Even with air filter off, as soon as I put that 2 inch plastic intake pipe on the carb even with filter off, it won’t run rev up, it only idles perfectly. I’m lost lol.

[@lall427]

This was happening to me..after I cleaned it and put a new carb kit in. So, when it was idling, I squirted in quick start and opened the throttle to rev it...got the fuel moving and unplug wtv or unstuck a value etc. Get the quick start to rev to higher!

[@excellenceinanimation960]

I just had mine taken apart and finally get it together. I go to run it and it barely moves at like 5000 rpm. One thing after another still doesn't start with the switch but starts first pull with cord.

[@zoriahruiz3393]

Did you figure it out? I have the same exact issues

[@excellenceinanimation960]

@@zoriahruiz3393 yep was water in the case! There is a little drain plug that is plastic. I think mine was red. Works great after this. I hope no much water damage.

[@zoriahruiz3393]

@@excellenceinanimation960 as in the motor? Or

[@excellenceinanimation960]

@@zoriahruiz3393 no just the clutch. If there is water in the clutch you may want to check the pull start. There should be a nut you can loosen to drain water.

[@eduardobuera4592]

Tendrás reglaje de la luz de válvulas de escape y admisión?

[@TitaniummanGarage]

The valve clearance is .006

[@kennyphillips8603]

Wait!!! You work? Travis says he does all the mechanicals ??

[@TitaniummanGarage]

So he likes to think. But we rocked out 5 machines today.

[@user-cf3qj2bd4i]

​@@TitaniummanGarage I want to talk to you

[@bradyduncan7523]

What if mine is doing the same thing and the cam isn't worn out. All 3 lobes are fine. All the same size from eyeballing it. So what else would cause mine to run slow and have no pulling power??

[@big_watson2015]

I’d like to know as well

[@Nunya_Beezwax]

Fuel pump

[@bradyduncan7523]

@@Nunya_Beezwax so I changed the carb and fuel pump. Now I have to tune it somehow and figure out why my coolant fan no longer kicks on

[@Nunya_Beezwax]

@@bradyduncan7523 most likely the same reason mine quit. The coolant sensor in the radiator. You can see if the fan is still good by disconnecting the sensor, and using a jumper wire to connect the two wires. Fan should come on with the key on. If not, you have a bad fan.

[@bradyduncan7523]

@@Nunya_Beezwax I will give that a shot!

[@dynasteve1242]

Hey brotha, I have an 03-04 600. It overheats no matter what. Would it do any harm if I ran without a thermostat?

[@TitaniummanGarage]

It could work. But it will be running cool and not at proper operating temperature.

[@user-cf3qj2bd4i]

I want to talk to you

[@Doinityourself]

Oh Polaris.... never stop making junk. Such a shame.