I just recently bought a 98 Sportsman 500, previous owner said he couldn’t get it to run on his own without using starter fluid. I got it for $700 after hearing it turn over and knew it needed a carb clean or rebuild so I bought a carb rebuild kit and just installed it yesterday only to find out as I’m starting it up it’s spewing and leaking gas out of the header pipe. I was able to remove the main jet and the other jet that I forget what is called but was not able to remove the jet that you mentioned in this video all I was able to do was spray carb cleaner down in it and hope it would clean it out, on another note the jets were not labeled in my rebuild kit to match size of the old jets so I had to choose based of the size to my eye. Also the new C Clip they provide in the kit for the slide pin on the throttle is suppose to go in a certain groove to either richen or lean out the motor I set mine where the previous one was and that was the second groove from the bottom, I’m not sure if one of these issues is causing my gas leak out of my header pipe, any ideas?
Josh Albright when you mention header pipe is that the exhaust you are referring to? Is it leaking out just sitting still without trying to crank? If you have gas coming out of the carb it’s usually the needle that is not shutting off the fuel in the seat or the float is not working.....all on the bottom of the carb......you would half to take off the bowl and check and see if those items are working like they should.....
Fearlessfly 100 Yes not exactly where the header mates to the head but where the spring is on the header pipe once it makes its bend to run back towards the rear of the bike and it’s only doing it when the gas is turned on and I’m turning it over
Josh Albright you are gonna half to take off the top of the carb and remove the diaphragm that rides in the jet block......there’s an opening inline with the choke cable......the plug should move back and forth in the opening......if not then that might need to be repaired........
I have a 1999 ranger 500 which I think is the same motor, and the thing runs really rich when I go downhill and starts fouling the spark plug. I reset the float level so it won't do that and now it runs too lean on flat ground but runs fine down hill. Do you know what i can do to fix this problem?
I have tried with a magnet and no joy. I am confused as to where it would have landed, because the lower sprocket, where the chain is driven from, appears to be in a separate compartment where no oil can be, otherwise, if oil is there, the stator would quickly have a short circuit.
By the way, any of you guys, and or girls, know where there is a Polaris ATV wrecker to buy second-hand parts from? Things like footwells, flywheels, stators, cdi's, etc.
Thanks for watching....do you mean it will not run? Did you take the jet out in the middle? If everything is squeaky clean and installed then make sure you have fuel going to the carb.....
@@fearlessfly100 thank you sir, I am still checking as to why there is a spark as soon as it turns over and then it stops. Still rechecking elect.syst. to try & figgure'n it out.
@@richardhillier9748 stay tuned I have an engine out of another 500 HO that I’ve completely torn down and split to put a crankshaft and top end in because of getting too hot at one point.......
Amigo, Have you ever come across a situation where the timing chain top sprocket bolts have sheared and fallen into the engine? How did you remove the bolts from the engine so they do not do any further damage?
@@fearlessfly100 well it ran better than this one but I had the unit in garage changing rear bushings and decided to do some other maintence. figured I'd take the carb off and give a good cleaning. clumsy me dropped it on the concrete after I removed the bowl and broke one of the eats off that home the float pin. tired to souder it but it wouldn't stick
@@johnromans732 oh ok......to be honest with you I've ran into the same problem with aftermarket carbs.....they just didn't work right at higher rpms.......there is a product that I've used on metal parts that's called quick steel......it's a 2 part mix in a tube......if you have the broken part maybe you can clean it up and use that to put it back together......it's probably gonna be a pain as small as the parts are and to sand the material down......but it's worth a shot
Was that jet you said was clogged why no start , ? After cleaning and reinstall did it fire up , im working on mine right now and it was running and then died out riding out of shop so i did find jet clogged Hope that was it and it starts
Yes the jet was clogged up....that’s why it did not run on it’s own....after I cleaned it out I had to crank on it a little to get fuel back into the bowl....I also had to pull the choke slightly to help get it fired back up.....
I am having starter issues with my 1999 sportsman 500 while the engine is running the starter will get as hot as a firecracker but only while the engine is running. And the starter switch is not sticking so I know that is not the problem and the starter bendix is not sticking either so is something grounding out possibly while it is running?
Cole Layden Thanks for watching.....it’s close to the crank case so it’s gonna be as warm as the engine is.....the heat will transfer to the starter from the engine and be hot as the engine is....
Fearlessfly 100 well that’s what I thought but it burnt up 2 starters from overheating and I took them apart and the brushes were all burnt up and the starter was extremely hard to turn but now they don’t work at all. It never did that before but now it’s burning up starters while it’s running but the starters don’t even get warm while you are cranking it over, so I don’t know
Cole Layden if you have a volt meter check if there’s voltage at the starter.....if there is then check if there’s the same thing happening at the solenoid......there shouldn’t be any voltage at the starter or starter side of the solenoid until you push the button to start......
Fearlessfly 100 but if there was constant voltage as Soon as I turn the key on it will just start cranking without hitting the start button but it only cranks if I hit the start button. And yes I tested that and there is no constant power going to the starter unless I hit the start button
Cole Layden when the engine is running.....does the starter feel like it’s still turning? Like the bendix is is stuck and the engine is turning the bendix and the starter with out applying power to it?
I didn't try to get aggressive with it.....I ran it down finger tight first with a small screw driver....then just barely tightened it a little more....thanks for watching.....😁
I just recently bought a 98 Sportsman 500, previous owner said he couldn’t get it to run on his own without using starter fluid. I got it for $700 after hearing it turn over and knew it needed a carb clean or rebuild so I bought a carb rebuild kit and just installed it yesterday only to find out as I’m starting it up it’s spewing and leaking gas out of the header pipe. I was able to remove the main jet and the other jet that I forget what is called but was not able to remove the jet that you mentioned in this video all I was able to do was spray carb cleaner down in it and hope it would clean it out, on another note the jets were not labeled in my rebuild kit to match size of the old jets so I had to choose based of the size to my eye. Also the new C Clip they provide in the kit for the slide pin on the throttle is suppose to go in a certain groove to either richen or lean out the motor I set mine where the previous one was and that was the second groove from the bottom, I’m not sure if one of these issues is causing my gas leak out of my header pipe, any ideas?
Josh Albright when you mention header pipe is that the exhaust you are referring to? Is it leaking out just sitting still without trying to crank? If you have gas coming out of the carb it’s usually the needle that is not shutting off the fuel in the seat or the float is not working.....all on the bottom of the carb......you would half to take off the bowl and check and see if those items are working like they should.....
Fearlessfly 100 Yes not exactly where the header mates to the head but where the spring is on the header pipe once it makes its bend to run back towards the rear of the bike and it’s only doing it when the gas is turned on and I’m turning it over
Make sure your choke is working properly......if it’s being over choked it will do what you are describing.......
Fearlessfly 100 How do I check for that?
Josh Albright you are gonna half to take off the top of the carb and remove the diaphragm that rides in the jet block......there’s an opening inline with the choke cable......the plug should move back and forth in the opening......if not then that might need to be repaired........
Nice job Feoras, customer will be happy!
Kyle Davis thank you for watching....😁
Further to my question below, please add, obviously without removing the engine and pulling it apart, that would be a no brainer!
Great Job 👍. Brother. Enjoyed Your Video
I have a 1999 ranger 500 which I think is the same motor, and the thing runs really rich when I go downhill and starts fouling the spark plug. I reset the float level so it won't do that and now it runs too lean on flat ground but runs fine down hill. Do you know what i can do to fix this problem?
Mine is a completely new carb,it starts up fine,but maybe 20-30 secs later it starts overfilling
Adjust the tab on the float where the needle sits and see if that makes a difference......
I have tried with a magnet and no joy.
I am confused as to where it would have landed, because the lower sprocket, where the chain is driven from, appears to be in a separate compartment where no oil can be, otherwise, if oil is there, the stator would quickly have a short circuit.
By the way, any of you guys, and or girls, know where there is a Polaris ATV wrecker to buy second-hand parts from?
Things like footwells, flywheels, stators, cdi's, etc.
Got similar, but cleaned and still wont crank. Cold psi is 58-60. Good spark, timing on, valve lash good.?? Help!!!
Thanks for watching....do you mean it will not run? Did you take the jet out in the middle? If everything is squeaky clean and installed then make sure you have fuel going to the carb.....
@@fearlessfly100 did, went so far as to use a china clone. Now i have spark, but it's intermittent
@@richardhillier9748 if the spark is intermittent then there might be an issue there......
@@fearlessfly100 thank you sir, I am still checking as to why there is a spark as soon as it turns over and then it stops. Still rechecking elect.syst. to try & figgure'n it out.
@@richardhillier9748 stay tuned I have an engine out of another 500 HO that I’ve completely torn down and split to put a crankshaft and top end in because of getting too hot at one point.......
Amigo,
Have you ever come across a situation where the timing chain top sprocket bolts have sheared and fallen into the engine?
How did you remove the bolts from the engine so they do not do any further damage?
Maybe go fishing with a flexible magnet?
what is the bigger looking jet do that is located between the float and your jet that is stopped up
That is the main jet for the carb
@@fearlessfly100 ok. I'm trying to tune my 01 500. replaced the mikuni carb with aftermarket. it's starts and idles fine but boggs down when reving
@@johnromans732 was the old one not able to be repaired?
@@fearlessfly100 well it ran better than this one but I had the unit in garage changing rear bushings and decided to do some other maintence. figured I'd take the carb off and give a good cleaning. clumsy me dropped it on the concrete after I removed the bowl and broke one of the eats off that home the float pin. tired to souder it but it wouldn't stick
@@johnromans732 oh ok......to be honest with you I've ran into the same problem with aftermarket carbs.....they just didn't work right at higher rpms.......there is a product that I've used on metal parts that's called quick steel......it's a 2 part mix in a tube......if you have the broken part maybe you can clean it up and use that to put it back together......it's probably gonna be a pain as small as the parts are and to sand the material down......but it's worth a shot
Was that jet you said was clogged why no start , ? After cleaning and reinstall did it fire up , im working on mine right now and it was running and then died out riding out of shop so i did find jet clogged Hope that was it and it starts
Yes the jet was clogged up....that’s why it did not run on it’s own....after I cleaned it out I had to crank on it a little to get fuel back into the bowl....I also had to pull the choke slightly to help get it fired back up.....
I am having starter issues with my 1999 sportsman 500 while the engine is running the starter will get as hot as a firecracker but only while the engine is running. And the starter switch is not sticking so I know that is not the problem and the starter bendix is not sticking either so is something grounding out possibly while it is running?
Cole Layden Thanks for watching.....it’s close to the crank case so it’s gonna be as warm as the engine is.....the heat will transfer to the starter from the engine and be hot as the engine is....
Fearlessfly 100 well that’s what I thought but it burnt up 2 starters from overheating and I took them apart and the brushes were all burnt up and the starter was extremely hard to turn but now they don’t work at all. It never did that before but now it’s burning up starters while it’s running but the starters don’t even get warm while you are cranking it over, so I don’t know
Cole Layden if you have a volt meter check if there’s voltage at the starter.....if there is then check if there’s the same thing happening at the solenoid......there shouldn’t be any voltage at the starter or starter side of the solenoid until you push the button to start......
Fearlessfly 100 but if there was constant voltage as Soon as I turn the key on it will just start cranking without hitting the start button but it only cranks if I hit the start button. And yes I tested that and there is no constant power going to the starter unless I hit the start button
Cole Layden when the engine is running.....does the starter feel like it’s still turning? Like the bendix is is stuck and the engine is turning the bendix and the starter with out applying power to it?
How tight did u tighten the jet??
I didn't try to get aggressive with it.....I ran it down finger tight first with a small screw driver....then just barely tightened it a little more....thanks for watching.....😁
I just bought one lol 😆 😅 😂