Thank you.. very helpful video to increase my confidence in tackling this. Have a 97 Xplorer 500 that I am fighting to get running despite a new stator, flywheel, battery, coil, plug wire, plug, filter, fuel pump, carburetor, etc. Can’t get it to start without taking carb off and dumping fuel. Going to tackle the internals..
Hey there, just bought my first Polaris 500, this is awesome video for. New owner, don’t plan on rebuild but seeing you assemble this helps understand the internals. Thanks so much for sharing your wisdom ..
I enjoy your videos. Recently bought a 98 Sportsman 500 and yes I have had my hands full. You explain everything well keep it up I will be a Pro Polaris Mechanic! ha ha
got a 500 bottom end. connecting rod is in great shape. no end play and very little side to side. the main bearings are good to, turn smooth and no up and down play. but the whole cam shaft can slide left and right in the case maybe a half mm. what you think is wrong? i never split the case. you think something is worn, or maybe missing a shim? or should i just send it lol. have you ever experienced slight left and right movement in and out of the bearings on any of your engines. my other bottom end doesn't move at all.
I’m pretty late on this but I’ve never messed with engines and this doesn’t look to bad. What all part need replaced when doing a bottom end rebuild,and do you think it’s necessary to buy a new timing chain when doing this
I have a 2018 sportsman 450 and when it's idling its making a clicking sound but it goes away when I give it gas. Would it be the valves that's making the noise
I really appreciate the video its very helpful. i do have a question do you bottom out the nut on the water pump impeller? it seems like it presses the impeller onto the housing? thanks in advance for any feedback!
the 425 "engine" crankcase. Was the crankshaft assembly and connecting rod all 425 as well? so you just changed the piston and just. The cams are the same but the valves are different numbers between the 425 and 500. Would've been nice to confirm if the valves were the same size with dial calipers.
I've got a scrambler 500 ho 4x4 wanna rebuild it I googled the compression ratio and it's 10:8.1 but every piston I see that will work for it no matter where I look is 10:2.1, is that the actual compression ratio?... really don't wanna be down on power and speed.
You are so knowledgeable about the 2000 Sportsman 500. I wonder if you could give me some guidance and direction on a problem I have. I dropped a paper cap from a fuel stabilizer into the gas tank by accident. I can't think of any way to get it out. How hard is it to get the gas tank off. Or maybe you have another way to get it out. I feel like I need a trick here. I really don’t want to take the tank off. I have taken the seat off and the side shields. I was hoping that I wouldn't have to remove all of the plastic shields.
A paper cap? there are screens on the fittings going to fuel lines that stick up. you have to remove plastics to get tank off. but if it doesn't dissolve the screen should keep it from blocking anything
Subscribed Sir. Really like your instructions that are clear and filled with experiences, super helpful. To test sparks on Polaris predator 500, with key harness removed (ordered a new one), is it going to spark? Any other items are restricting spark?
I have a 2001 Sportsman 500 that needs a timing chain but I'm trying to get the fly wheel off but not sure which direction to turn the nut holding fly wheel on. Hoping you can help. Thanks John
Thank you, I will take a look at removing the cam and see what happens with the oil. What about the sheared bolt from the timing chain that fell inside the engine? Has it happened to you, as well? I trying to figure out a way of extracting it from the engine without having to dismantle the whole engine, too painful, mate!
No I haven't. I have had to pull out piston skirt out of the engine. If you pull the cylinder and piston you should be able to get a magnet down to the bottom of the case. If you have a magnetic wand. I ended up splitting my case. Your just looking for a bolt so It might not be that bad.
Hey T, thanks for your videos!! Would the 2007 sportsman 450 fall into this category of using a 500 top end? There's not a lot of information on it. Any suggestions? Thanks, Jim
I am struggling to find a torque spec for the rocker arm tower bolts. I looked through a manual online and found 9 ft lb. that seems to be very light to me and want to be certain before putting it back together. If it is only 9 ft lb would it benefit having some blue lock tight to keep the bolts from coming out?
Hello I've subscribed to your channel great content but I have a question what is the standard Piston ring gap for a 98 Polaris 500 because i have the manual and it say that its supposed to be gapped at 0.20/0.36 is that correct Thanks for your time keep the videos coming
I got a 2013 Polaris sportsman with fi with 7600 miles on it, so with that said, it got to where it wouldn't cold start without holding the fuel down on it, so I would do a valve adjustment and it would be alright for about a month, or so, and then the intake valves would tighten back down, well, finally I bought new valves, and done a valve lap and installed them. If it starts with the same problem, do you think I ought to buy a new head and new valves to cure the problem?
Can you remove the chain guide without removing the head? Also I need to replace the timing gear on the crank and the split nut is proving difficult in to coming off. Is there a spanner socket for it?
The right side chain guide is positioned under the head so you have to remove the head to get it out. The left or topside could possibly come out without removing the head with the chain out of the way. There should be a socket on ebay for that goofy nut. Or you could make one. Some guys make them out of pipe and notch the end out.
Subbed . Man you have confirmed my tgeory same part different number thing! Ive seen that with a lot of polaris stuff out there particularly sprocket and axle bearing carriers and what not. I have a 2000 polaris 500 sportsman 6x6. Chain snapped busted rh of the gear case. My thougts are i had an alignment issue on tge new sprocket and the output shaft bearing. Got a lot of slop in that output shaft now. I cant find my gear case rh anywhere! Do you have a source for that part? Id like to rebuild the trans while i got this down. Also the sprocket was replaced with a superceded part on that middle axle . The old one was seized to the axle and i couldnt get it off. I bought this used from a guy had bad bearings back there and he just rode it that way for god knows how long. Well when it came tim to fix this , i ran into siezed sprocket on thw axle and rhe biggest of pullers only warped the old sprockt didnt budge it . So i had to cut the axle bearing carrier in half straight through the axle. The acle was badly damaged anyway so i was gonna have to replace it. But i could not get it out. The locking hubs were siezed up on one side as well . It was a real pain to get that back together. Well when i did i realized the sprocket would not line up proper. I need a spacer any idea where i can find one of those?
Great video quick question on the jug itself the 4 short bolts what are the torque numbers? I know the head bolts have a special torque sequence on the video you posted I just can’t find any specs on the jug bolts torque specs
Question. After putting my 97 Sportsman back together, I learned the oil seal is leaking (oil leaking out of weep hole). Can this seal be replaced from the impeller side without disassembling the engine and splitting the case?
I've been asked that a lot. There is a way but it involves a tin snips and a flat screwdriver. It usually ends up in scratching the surface. If you do it that way put a light coat of gasket maker down. Just a thin coat. It says not to but there is a chance if you scratch the surface the mechanical water pump seat will leak.
Really liked the video on engine rebuild. I just have on question on the torque specs for the cylinder base bolts. I cannot find them anywhere. Or do the need torqued at all. I'd really would appreciate if you could reply what they are.
So Polaris made a 425 that had a 5 speed auto clutch trans I just wonder if u could make a 500 ho using a 500 jug cam and carb that thing would be wicked fast
Good work! I have learned alot from your videos. I've got a real teaser for ya.. 02 500 ho just rebuilt topend, namura piston gaskets etc. Bored over as well. Anyway, runs great! But will only start with recoil, key cranks engine but no fire.. Any ideas?
Thats a new one for me. I'm gonna have to research that one. Interesting! Refresh my memory. does the 02 have the key that turns all the way to start it like a car? Or is it the push button style? something in the wiring isn't reading correctly.
@@TitaniummanGarage Turn key ignition, I've tried jumping power from battery, directly to starter with key in hot position, still no fire, seeing week spark while cranking with starter, strong spark with recoil..pretty stumped. I can start it but my girls can't. I appreciate your thoughts and suggestions very much!
Great video, i just bought a 4x2 scrambler 500 and the motor is locked up.. at least i know how to tear into it now.. is there a full rebuild kit out there? Thanks!
Which oil hose do you pinch to prime the oil pump? Merry Christmas, don’t drink too much Budweiser, mate. How is Covid-19 doing in your area? By the way? How do you pull the crankshaft apart? And putting it back together? Hasta la vista amigo. Ándele ándele, arriba arriba
Have a Merry Christmas as well. We are getting hit hard in Wisconsin. I use a press to remove the crankshaft out of the block. You could use a big rubber mallet too.
@13:10 you say: "Most of the other parts are (from) 425." I´m planning to do the same upgrade, what parts besides the jug and piston do I have to change on my 425? Thank you for great content!
What kind of crankcase sealant did you use? Polaris OEM Crankcase Sealant is about $50 for a small tube. Is the OEM sealant necessary or is there an acceptable alternative? Great video. I'm using it to help me rebuild my Magnum 330. Not exactly the same but a lot of what you show in your video is helpful. Thanks!
Check the cam, gears, inspect the area for any damage and make sure the woodruff key didn't break. You also have to consider why did it break? Piston shot? Cam seized?
Yes. The only difference is the chain tensioner. The 05 is smaller. Nothing to worry about. Other than that everything is identical. I just rebuilt one.
hey there enjoy your vids! I have a question if you dont mind. I have a 2001 pol. sports. 500 ho. Need to replace the cam. Am looking at a kit from Niche. Have you used them? What would you recommend? Thanks!..
The 425 crank has 5mm less stroke, so essentially you've created a 465cc engine. Great news for 425 guys since there are kits out there for $90 that include the jug, piston+rings, and gaskets. Funny that it all just bolts right up and the piston has the proper deck height.
Hey buddy I’m working with a 99 sportsman 500 oil is leaking from front exhaust manifold and when it runs it blows white smoke. Could it be my piston rings or a head gasket? Any knowledge or suggestions is greatly appreciated I’m debating on rebuilding the whole engine
Hi again, do you happen to have a dowel pin lying around that you may not need? Ia m short of one. How much do you want for it, if you have it, and how much to send it to Sydney, Australia? Thank you
Is this the torque value for the first 4 bolts he torqued before moving to the 4 bolts of the head? Not asking because you didn’t explain it well enough just want to make sure because I’m having trouble finding the torque value for the bottom 4 bolts lol
I have an 03 500 that I picked up and it must have overheated in the past because the piston pin was welded into the crankshaft. I took the water pump cover it inspect the propeller and noticed what looks like hairline cracks . The are no visible cracks on the outside of the crankcase. Would you say this is a big issue?
You have to ask. Why did it over heat? If the mechanical seal wasn't leaking and those hair line cracks are by the pump. I dont know If I would trust it.
One more question Sir, How can you tell when the oil pump is not working? The pressure is minimal and I had my Sportsman 500 HO shear the timing chain sprocket, I guess it seized out of lack of oil.
I had one that snapped the chain. I would replace the pump. Also check the hole where the oil comes in by the head .see if it's not plugger. It should be by the cover to pull cam out.
so you said head and cam shaft was the same on 425 as 500 is only the valves different ?? are they larger on a 500 .?? asking because 425 parts are like 1/2 price of 500 parts i find .
Great information! You just got a faithful subscriber! :) I hope you can answer a question for me and save me some time. I recently rebuilt a 2003 Polaris 700. It has been running fine now I have water in the oil. I can see seepage from the side stator casing. Do you think it would be the oil seal or head gasket?
Lol. That what I thought. But yeah..the mechanical water pump seal leaks, gets in the engine and oil. The 70's are known for it. I have a video how to replace it.
I have a serios problem I hope you can give me an idea ... a friend broke the water pump shaft on my polaris predator 500 2007 an I open the cases put everything back together an when i tide the case bolts the piston won't turn it gets so hard the. I untide them back an it move do you have an idea what can be holding it
If they are Polaris isn't doing it very well. LOL. I've done quite a few and they all slide in. Some with a little persuasion. The 400 2 strokes are pressed in that I can tell ya. I need a press to get them out.
This is a great video. Just subscribed. Just got my 1st Sportsman 500 w 900 hours. The engine has a little knock. (It's not a deep knock like low end.). I've noticed other Sportsman 500's on UA-cam have the same sound. What is it? What do I need to do? Preventative wise?
@@TitaniummanGarage Started it up again today. Sound goes away when rev it but it smokes around the head/valve cover. Shut it down right away. I ordered cam & rockers. Should I pull the head to see if there is piston slap? Pretty sure the knock is from the engine.
Have you ever come across the issue of no power to the solenoid, you wait a while and it fixes itself, but if you crank it a few times and the engines has not fired up, the same no power problem resurfaces. What is going on?
No power to the primary or secondary of starter solenoid? If there isn't power at the solenoid, the motor won't crank (turn). If it's no spark, ( not starting) when hot, it could also be the coil or spark plug....
Did you use a crank and rod from a 425? If so that should be a 465cc. I’ve been wanting to build one for a while. Basically put a 500 top end on a 425. Then use the h.o cam and intake /carb.
@@eyeballengineering7007 have you calculated the compression to be 7:1 if using a 425 bottom end and 500 top end ? I was always curious. I think I remember the 425 being 8:1 and the 500 is 10:1 roughly.
@@gshew6769 no, I went down the rabbit hole last night. The cylinder height is apparently the same. It's only the rod length that changes. So it should actually increase the compression directly between what the Magnum 425 and the 500 have stock. The magnum is 9.2x1 while the 500ho is 10.2x1. so the 465 with the same chamber and deck height should be approximately 9.7x1. I could not find the chamber size or the head gasket thickness. When I get my motor yanked apart I'll know a lot more. That's why the numbers are approximate.
@@eyeballengineering7007 very interesting, keep me updated my old 400 is pretty lazy and I’m considering doing a rebuild on it and adding some stuff like a cam , bigger carb etc. might even do some at home port polishing.
Thank you.. very helpful video to increase my confidence in tackling this. Have a 97 Xplorer 500 that I am fighting to get running despite a new stator, flywheel, battery, coil, plug wire, plug, filter, fuel pump, carburetor, etc. Can’t get it to start without taking carb off and dumping fuel. Going to tackle the internals..
Oh excellent, no nonsense instructions to service repair this Polaris engine.
Appreciate you sharing this with us.
Thank you very much.
Your Welcome. Glad to help.
Excellent Video, Rebuilding a Suzuki LTA750 top end and need to know what to look out for. Greatly appreciated.
Such a helpful video I will be watching this a few times amongst others on your channel, thanks man!
That's Awesome. Glad to Help.
Super awesome video thank you so much for sharing
Hey there, just bought my first Polaris 500, this is awesome video for. New owner, don’t plan on rebuild but seeing you assemble this helps understand the internals. Thanks so much for sharing your wisdom ..
Como ponerlo a tiempo el mottor
Great video thanks for sharing you make it look easy
Excellent video and explanation! Keep em coming
I enjoy your videos. Recently bought a 98 Sportsman 500 and yes I have had my hands full. You explain everything well keep it up I will be a Pro Polaris Mechanic! ha ha
Sweet!
Thanks for the great video Brother...
Wish I could hangout with this guy and learn from him
Great stuff bud!
Good job !!!
This is awesome I have a 425 low mile quad happen to have a spare engine out of a scrambler🇺🇸🇺🇸🇺🇸🇺🇸👍🏻
got a 500 bottom end. connecting rod is in great shape. no end play and very little side to side. the main bearings are good to, turn smooth and no up and down play. but the whole cam shaft can slide left and right in the case maybe a half mm. what you think is wrong? i never split the case. you think something is worn, or maybe missing a shim? or should i just send it lol. have you ever experienced slight left and right movement in and out of the bearings on any of your engines. my other bottom end doesn't move at all.
I love your video. I just subscribed. I have a 450 sportsman and
I like your style! I have a 2006 Sportsman 500 EFI that's locked up, where would you start? Thanks
Do you have a video on replacing the water pump seal on a Polaris Sportsman 500?
Wish i had this video a year ago! Great tutorial! Do you ever replace the plastic impeller with the All Balls metal one?
Yeah! Definitely the way to go. Great product.
I’m pretty late on this but I’ve never messed with engines and this doesn’t look to bad. What all part need replaced when doing a bottom end rebuild,and do you think it’s necessary to buy a new timing chain when doing this
I am talking about the dowel pins that go in the crankcase, the solid one, part number 3084840.
What do you use to clean up the crankcase prior to build?
Really helpful! I’m completely tearing down my 96 500! Do you have any guides on rewiring everything?
Now that's a big question. I've rewired a whole atv. lots of wires. what are you asking specifically?
I have a 2018 sportsman 450 and when it's idling its making a clicking sound but it goes away when I give it gas. Would it be the valves that's making the noise
Rebuilding my 425 and might get the 500 piston & jug. Did you use the 425 carb & exhaust or did you have to upgrade to the 500 carb and/or exhaust?
I really appreciate the video its very helpful. i do have a question do you bottom out the nut on the water pump impeller? it seems like it presses the impeller onto the housing? thanks in advance for any feedback!
I just snug it up with locktite. you don't want it rubbing against the case. you might have to back it off a little
the 425 "engine" crankcase. Was the crankshaft assembly and connecting rod all 425 as well? so you just changed the piston and just. The cams are the same but the valves are different numbers between the 425 and 500. Would've been nice to confirm if the valves were the same size with dial calipers.
I've got a scrambler 500 ho 4x4 wanna rebuild it I googled the compression ratio and it's 10:8.1 but every piston I see that will work for it no matter where I look is 10:2.1, is that the actual compression ratio?... really don't wanna be down on power and speed.
When I removed my crank my bearings stayed on the crank. The double bearings on the pto side. Did this happen to you and if so how’s you get them off.
excellent
Do a 3 part vid bud im gonna want more information . Do you buikd gearcases as well?
You are so knowledgeable about the 2000 Sportsman 500. I wonder if you could give me some guidance and direction on a problem I have.
I dropped a paper cap from a fuel stabilizer into the gas tank by accident. I can't think of any way to get it out. How hard is it to get the gas tank off. Or maybe you have another way to get it out. I feel like I need a trick here. I really don’t want to take the tank off.
I have taken the seat off and the side shields. I was hoping that I wouldn't have to remove all of the plastic shields.
A paper cap? there are screens on the fittings going to fuel lines that stick up. you have to remove plastics to get tank off. but if it doesn't dissolve the screen should keep it from blocking anything
Subscribed Sir. Really like your instructions that are clear and filled with experiences, super helpful. To test sparks on Polaris predator 500, with key harness removed (ordered a new one), is it going to spark? Any other items are restricting spark?
You'll need the key unless you jump a wire to 2 reds. the kill switch will restrict it as well.
I have a 2001 Sportsman 500 that needs a timing chain but I'm trying to get the fly wheel off but not sure which direction to turn the nut holding fly wheel on. Hoping you can help. Thanks John
Thank you, I will take a look at removing the cam and see what happens with the oil.
What about the sheared bolt from the timing chain that fell inside the engine? Has it happened to you, as well? I trying to figure out a way of extracting it from the engine without having to dismantle the whole engine, too painful, mate!
No I haven't. I have had to pull out piston skirt out of the engine. If you pull the cylinder and piston you should be able to get a magnet down to the bottom of the case. If you have a magnetic wand. I ended up splitting my case. Your just looking for a bolt so It might not be that bad.
I have 2012 think the balancer shaft gear spoon. How can I find out if it did
Hey man thanks for the rebuild of the 500. I am curious what brand of impact wrench do you use .
I have a Milwaukee and a Dewalt.
Torque spec for cylinder jug bolts? Did I miss that?
Hey T, thanks for your videos!!
Would the 2007 sportsman 450 fall into this category of using a 500 top end? There's not a lot of information on it. Any suggestions?
Thanks,
Jim
I haven't worked on a 450 so I'm not sure.
Thanks helped alot
I am struggling to find a torque spec for the rocker arm tower bolts. I looked through a manual online and found 9 ft lb. that seems to be very light to me and want to be certain before putting it back together. If it is only 9 ft lb would it benefit having some blue lock tight to keep the bolts from coming out?
I would do that just to be safe.it is an aluminum block so that could be right.
great video buddy! Excited for the next video!
Thanks Man! Glad you enjoyed it.
Hello I've subscribed to your channel great content but I have a question what is the standard Piston ring gap for a 98 Polaris 500 because i have the manual and it say that its supposed to be gapped at 0.20/0.36 is that correct Thanks for your time keep the videos coming
Depends what piston you buy.
I got a 2013 Polaris sportsman with fi with 7600 miles on it, so with that said, it got to where it wouldn't cold start without holding the fuel down on it, so I would do a valve adjustment and it would be alright for about a month, or so, and then the intake valves would tighten back down, well, finally I bought new valves, and done a valve lap and installed them. If it starts with the same problem, do you think I ought to buy a new head and new valves to cure the problem?
Sounds like your chain might be streached.Try to replace the chain. clean the carb and check the choke adjustment.
Can you remove the chain guide without removing the head? Also I need to replace the timing gear on the crank and the split nut is proving difficult in to coming off. Is there a spanner socket for it?
The right side chain guide is positioned under the head so you have to remove the head to get it out. The left or topside could possibly come out without removing the head with the chain out of the way. There should be a socket on ebay for that goofy nut. Or you could make one. Some guys make them out of pipe and notch the end out.
Subbed . Man you have confirmed my tgeory same part different number thing! Ive seen that with a lot of polaris stuff out there particularly sprocket and axle bearing carriers and what not. I have a 2000 polaris 500 sportsman 6x6. Chain snapped busted rh of the gear case. My thougts are i had an alignment issue on tge new sprocket and the output shaft bearing. Got a lot of slop in that output shaft now. I cant find my gear case rh anywhere! Do you have a source for that part? Id like to rebuild the trans while i got this down. Also the sprocket was replaced with a superceded part on that middle axle . The old one was seized to the axle and i couldnt get it off. I bought this used from a guy had bad bearings back there and he just rode it that way for god knows how long. Well when it came tim to fix this , i ran into siezed sprocket on thw axle and rhe biggest of pullers only warped the old sprockt didnt budge it . So i had to cut the axle bearing carrier in half straight through the axle. The acle was badly damaged anyway so i was gonna have to replace it. But i could not get it out. The locking hubs were siezed up on one side as well . It was a real pain to get that back together. Well when i did i realized the sprocket would not line up proper. I need a spacer any idea where i can find one of those?
So I have a 1995 425 and I keep breaking timing chains. What could be the problem?
my sportsman 500 is a bit noisy inthe topend im going to check valve clearance , but is it possible timing chain ?
Hello my question is what years does this work. I have a 2000 with a 425 motor
By the way, I was told by a Polaris dealer in Australia, that the Polaris oil pumps are so robust that they never fail.
Lies
Great video quick question on the jug itself the 4 short bolts what are the torque numbers? I know the head bolts have a special torque sequence on the video you posted I just can’t find any specs on the jug bolts torque specs
49 to 51 ft lbs
@@TitaniummanGarage thanks !
Is this pretty much the same procedure as a 06 sportsman 450 motor
Question. After putting my 97 Sportsman back together, I learned the oil seal is leaking (oil leaking out of weep hole). Can this seal be replaced from the impeller side without disassembling the engine and splitting the case?
I've been asked that a lot. There is a way but it involves a tin snips and a flat screwdriver. It usually ends up in scratching the surface. If you do it that way put a light coat of gasket maker down. Just a thin coat. It says not to but there is a chance if you scratch the surface the mechanical water pump seat will leak.
Sir question what is the torque lbs on the jug bolts ??? Can’t seem to find it working on this same build on a sportsman
46 to 50ftlbs
Are all the 400HO engine crankcases interchangeable with 500s? I have a 2009 sportsman 400HO. Does it mater what year 500 jug i use? Thanks
That I would have to research. The older 400's had shorter connecting rods. No it doesnt matter what 500 jug. they are all the same.
Really liked the video on engine rebuild. I just have on question on the torque specs for the cylinder base bolts. I cannot find them anywhere. Or do the need torqued at all. I'd really would appreciate if you could reply what they are.
46 to 49 ftlbs
@@TitaniummanGarage Thank you so much. Also your videos are great.
link to the cylinder jug torque video?
So Polaris made a 425 that had a 5 speed auto clutch trans I just wonder if u could make a 500 ho using a 500 jug cam and carb that thing would be wicked fast
I tried. Put an H.O carb and cam in it. wasnt much faster. Clutching it out right does the trick.
Good work! I have learned alot from your videos.
I've got a real teaser for ya..
02 500 ho just rebuilt topend, namura piston gaskets etc. Bored over as well.
Anyway, runs great! But will only start with recoil, key cranks engine but no fire..
Any ideas?
Thats a new one for me. I'm gonna have to research that one. Interesting! Refresh my memory. does the 02 have the key that turns all the way to start it like a car? Or is it the push button style? something in the wiring isn't reading correctly.
@@TitaniummanGarage
Turn key ignition, I've tried jumping power from battery, directly to starter with key in hot position, still no fire, seeing week spark while cranking with starter, strong spark with recoil..pretty stumped. I can start it but my girls can't. I appreciate your thoughts and suggestions very much!
Does a 97 polaris xpress 300 have a timing chain
thanks for the vid very helpfull id like to see a vid of it running bet its fast
Its a old video. I believe there is a link to click to see it running. Its pretty snappy off the line. I have a small dirt pile I jump it with.
Great video, i just bought a 4x2 scrambler 500 and the motor is locked up.. at least i know how to tear into it now.. is there a full rebuild kit out there? Thanks!
I think so. But beware..some cheap China parts come with it.
@@TitaniummanGarage great! You don't have a motor laying around do you? Lol
Which oil hose do you pinch to prime the oil pump?
Merry Christmas, don’t drink too much Budweiser, mate. How is Covid-19 doing in your area?
By the way? How do you pull the crankshaft apart?
And putting it back together?
Hasta la vista amigo. Ándele ándele, arriba arriba
Have a Merry Christmas as well. We are getting hit hard in Wisconsin. I use a press to remove the crankshaft out of the block. You could use a big rubber mallet too.
@13:10 you say: "Most of the other parts are (from) 425." I´m planning to do the same upgrade, what parts besides the jug and piston do I have to change on my 425? Thank you for great content!
The lower end was a 425. the upper was a 500 piston and jug.
What kind of crankcase sealant did you use? Polaris OEM Crankcase Sealant is about $50 for a small tube. Is the OEM sealant necessary or is there an acceptable alternative? Great video. I'm using it to help me rebuild my Magnum 330. Not exactly the same but a lot of what you show in your video is helpful. Thanks!
I normally use 3m gasket maker. You can get it at a auto parts store for 18 bucks.
What would be some damage to look for when a timing chain goes out?
Check the cam, gears, inspect the area for any damage and make sure the woodruff key didn't break. You also have to consider why did it break? Piston shot? Cam seized?
Is this the same for an 05 sportsman 500 ho? The engine seized up and had a rod knock before hand, needs a rebuild
Yes. The only difference is the chain tensioner. The 05 is smaller. Nothing to worry about. Other than that everything is identical. I just rebuilt one.
hey there enjoy your vids! I have a question if you dont mind. I have a 2001 pol. sports. 500 ho. Need to replace the cam. Am looking at a kit from Niche. Have you used them? What would you recommend? Thanks!..
Glad to hear you enjoy the vids. Niche is good. I've never had a problem with them.
@@TitaniummanGarage thank you sir!
Great video. By chance do you know the name for the tool that removes the crank timing chain sprocket?
Crank shaft nut tool socket. On ebay.
@@TitaniummanGarage thanks
The 425 crank has 5mm less stroke, so essentially you've created a 465cc engine. Great news for 425 guys since there are kits out there for $90 that include the jug, piston+rings, and gaskets. Funny that it all just bolts right up and the piston has the proper deck height.
Right. People don't believe it when I tell them I do that.
Can you provide a link to this kit I’m having issues finding it
@@TXCOyt There isn't a kit. I just bought the gaskets and piston on ebay and honed out the 500 jug.
Got my 425 running about a month ago with a 500 rebuild kit. Everything fit perfectly, has good power.
I have a qustion on a 96 sportsman 400
is that a yamaha snow blower ?
Hey buddy I’m working with a 99 sportsman 500 oil is leaking from front exhaust manifold and when it runs it blows white smoke. Could it be my piston rings or a head gasket? Any knowledge or suggestions is greatly appreciated I’m debating on rebuilding the whole engine
Actually It could be both. the oil ring or head gasket letting oil seep into cylinder.
Losing coolant, black oil, fouled plug (if so what color)? Air bubbles in radiator? Top end rebuild easy pretty easy and common
Ever build a Polaris 500 sportsman for a racing application?
No. I've always wanted to find a way to make it faster. I even tried a slide carb.
nice shirt mate
link to buy the manual?
How do you tighten up the crankshaft cam cog is it with a castle socket ??
you could buy a socket for it. I used a air hammer to do it.
@@TitaniummanGarage do you have a link or the name of the socket mate sorry to be a pest I really appreciate it
Hi again, do you happen to have a dowel pin lying around that you may not need?
Ia m short of one.
How much do you want for it, if you have it, and how much to send it to Sydney, Australia?
Thank you
No, Sorry I don't. I need all mine.
How do you tighten the bolt that hold the chain sprocket on?
Keep at TDC. Use loctite and snug them up. You should be able to tighten them in that position .
I bought a ,ran dry of oil, seized up 400 sportsman. What are the chances this would fix that?
Similar engine. Depending where it seized up
Cylinder jug aka cylinder- 4 large 12 point bolts= 46 ft-lbs
2 small 6 point bolts= 72 inch-lbs
Is this the torque value for the first 4 bolts he torqued before moving to the 4 bolts of the head? Not asking because you didn’t explain it well enough just want to make sure because I’m having trouble finding the torque value for the bottom 4 bolts lol
@@johnshepard1157 Yes. It's the bolts that screw in around the piston. They sit down in it.
I have an 03 500 that I picked up and it must have overheated in the past because the piston pin was welded into the crankshaft. I took the water pump cover it inspect the propeller and noticed what looks like hairline cracks . The are no visible cracks on the outside of the crankcase. Would you say this is a big issue?
You have to ask. Why did it over heat? If the mechanical seal wasn't leaking and those hair line cracks are by the pump. I dont know If I would trust it.
@@TitaniummanGarage thanks for the feedback. My thoughts too but wanted your opinion. Thanks again!
@@trentelliott1473 Sometimes you need another person to bounce an issue off of. I do it all the time. It's all good..
can you really reuse the cylinder head bolts ??
One more question Sir,
How can you tell when the oil pump is not working?
The pressure is minimal and I had my Sportsman 500 HO shear the timing chain sprocket, I guess it seized out of lack of oil.
I had one that snapped the chain. I would replace the pump. Also check the hole where the oil comes in by the head .see if it's not plugger. It should be by the cover to pull cam out.
Any chance that you forgot to prime the pump after an oil change? Requires pinching the reservoir hose for 10 seconds....
@@RayofallTrades That's a great tip. Thanks.
so you said head and cam shaft was the same on 425 as 500 is only the valves different ?? are they larger on a 500 .?? asking because 425 parts are like 1/2 price of 500 parts i find .
Same
@@TitaniummanGarage wow so the only thing differnt is the bore and pistion ?? sorry last time i'll bug you .
Great information! You just got a faithful subscriber! :) I hope you can answer a question for me and save me some time. I recently rebuilt a 2003 Polaris 700. It has been running fine now I have water in the oil. I can see seepage from the side stator casing. Do you think it would be the oil seal or head gasket?
I had one too. Its the Mechanical water pump seal. It could leak into the engine. But you said water right? Or coolant?
@@TitaniummanGarage Coolant.. I think water pump and water comes out of my mouth. You never hear them called coolant pumps. LoL
Lol. That what I thought. But yeah..the mechanical water pump seal leaks, gets in the engine and oil. The 70's are known for it. I have a video how to replace it.
700's. Not 70's.
@@TitaniummanGarage Thanks, you probably saved me some time attacking it at the right end first.
HOw can i get my Polaris magnum to you!?
7:00 , what about woodruff key?
I have a serios problem I hope you can give me an idea ... a friend broke the water pump shaft on my polaris predator 500 2007 an I open the cases put everything back together an when i tide the case bolts the piston won't turn it gets so hard the. I untide them back an it move do you have an idea what can be holding it
Did you change bearings and not set them proper depth? Forget shim placement or maybe order the wrong impeller? Are you sure timing chain is correct?
It was the bearing wasn't all in thank you so much I have it done
Hi. I picked up an 06 polaris 500 predator for $500. Engine needs rebuilt. Do you have anything on this engine by chance?
I haven't done any predators yet. They look like they would be fun though.
Does oil need to be drained before removing stator bolts?
Some oil will leak out if you dont. Not much.
can you pull the whole engine out of a sportsman or do you need to take the top end off to get it out?
You can pull the whole thing out.
@@TitaniummanGarage my secondary clutch is stuck you got an easy way to get it off
Great videos very helpful !! One question what are the torque spec on the jug bolts ?
There is a link in the video for another video I have doing the torque sequence.
How did that crank just slid in lol. Arnt they pressed
If they are Polaris isn't doing it very well. LOL. I've done quite a few and they all slide in. Some with a little persuasion. The 400 2 strokes are pressed in that I can tell ya. I need a press to get them out.
This is a great video. Just subscribed. Just got my 1st Sportsman 500 w 900 hours. The engine has a little knock. (It's not a deep knock like low end.). I've noticed other Sportsman 500's on UA-cam have the same sound. What is it? What do I need to do? Preventative wise?
It could be the clutch buttons. The lifters and chain make that noise as well when they are worn.
@@TitaniummanGarage Started it up again today. Sound goes away when rev it but it smokes around the head/valve cover. Shut it down right away. I ordered cam & rockers. Should I pull the head to see if there is piston slap? Pretty sure the knock is from the engine.
@@jaywinters2483 could very well be. I did a video years ago on a ATP. Turned out half the piston skirt was at the bottom of the engine.
One question, that head is from a Polaris Magnum 425..
Yes. Its the same as a 500.
You mentioned the crankcase was cracked. Did you just get one used crankcase half and mismatch it with yours or did you use a used pair?
I used a matching set. I have done a 400 2 stroke with missing match set and had no issues.
Miss matched
Thank you for the reply on an older video. I managed to crack the right side case while pushing in the counter balance bearings.
I got a 2013 sportsman 400 ho, can I make it a 500 or 570?
400 to 500 yes. Not sure about 570'S
Have you ever come across the issue of no power to the solenoid, you wait a while and it fixes itself, but if you crank it a few times and the engines has not fired up, the same no power problem resurfaces. What is going on?
Cdi box possibly?
No power to the primary or secondary of starter solenoid? If there isn't power at the solenoid, the motor won't crank (turn). If it's no spark, ( not starting) when hot, it could also be the coil or spark plug....
Did you use a crank and rod from a 425? If so that should be a 465cc. I’ve been wanting to build one for a while. Basically put a 500 top end on a 425. Then use the h.o cam and intake /carb.
Hopefully the rod is longer. He never checked deck height. Hopefully it's not 7x1 compression now. I am planning the same
@@eyeballengineering7007 have you calculated the compression to be 7:1 if using a 425 bottom end and 500 top end ? I was always curious. I think I remember the 425 being 8:1 and the 500 is 10:1 roughly.
@@gshew6769 no, I went down the rabbit hole last night. The cylinder height is apparently the same. It's only the rod length that changes. So it should actually increase the compression directly between what the Magnum 425 and the 500 have stock. The magnum is 9.2x1 while the 500ho is 10.2x1. so the 465 with the same chamber and deck height should be approximately 9.7x1. I could not find the chamber size or the head gasket thickness. When I get my motor yanked apart I'll know a lot more. That's why the numbers are approximate.
@@eyeballengineering7007 very interesting, keep me updated my old 400 is pretty lazy and I’m considering doing a rebuild on it and adding some stuff like a cam , bigger carb etc. might even do some at home port polishing.