Great video. I will be doing this starting this week. Your video will make this job much easier. 97 Sportsman 500. Thank you for taking the time to make this.
Very helpful considering i have my sportsman dismantled in my shed right now lol. Planned on checking the cam tomorrow and found this video at the right time.
Hello T Garage. Thank You SO Very Much for making this video. it is helping me Tremendously. i am replacing the head gasket in my 1995 polaris magnum 425 2x4 atv. this video and your video on replacing a head gasket are Realy Awesome. i have saved them to my you tube playlist. :)
Just wanted to say - thanks - Followed the video exactly and found my problem, You do a great service to those looking for a little differnt perspective and instruction. keep it up.
Hey T Garage, just want to say thanks for this video. I was at my wits end with my 99 scrambler 500. I had rebuilt the carburetor(a youtube video helped). I replaced a voltage regulator that was burnt up. I didn't know what else to do. My Dad suggested googling with the problem. I came across this video and I couldn't believe it. Watched it a couple of times to make sure it seemed like something I could tackle myself. I ordered the parts and replaced everything like you said to. This Memorial Day Weekend(2021), I rode the fourwheeler all over. I can't believe how much more power it has. To say thank you, just doesn't seem like enough. But thank you!
DUDE LIFE SAVER!!!!!!!!!!!!!!!!!!! I have a 1997 Polaris Explorer 500 that has no more power past half throttle, already cleaned carb thoroughly.. Same issue Start/Idle/first 25% of throttle is great.. but get to 1/2 to full throttle and I don't get any more higher RPMs or power. Some backfire when let off throttle but not much. So this is my next endeavor. Thanks so much for videoing this.
I have a 2002 500 HO are the parts the same for that as well most of the description just say fits all but it doesn't say anything about the 500 h.o. I just don't want to order the wrong part excellent video thank you so much!
Thanks, I'm in the middle of editing my next video. I will be a complete tear down. Start to finish, including how to remove the plastics. Stay tuned for it.
Great video, currently have my project polaris tore down to do this but was nervous to attempt. I feel much much more comfortable now doing it. Hopefully this fixes my issues with it and i'll have less than $500 in the whole damn thing lol.
i dont mean to be so offtopic but does someone know a method to get back into an instagram account..? I stupidly forgot my account password. I love any tips you can give me.
@Moises Alec I really appreciate your reply. I got to the site on google and im trying it out now. I see it takes a while so I will get back to you later with my results.
Hey T Garage, I rebuilt the top end with new piston and rings. Put it all back together but used old head gasket because it didn’t look bad, well it was so I had to pull head and replace it. It was starting and running fine just would bog at 1/2 throttle before, So I checked the cam and sure enough middle lobe was worn badly. So I bought a new cam and rockers. Put it all back together got it in time and set the valve clearance. Turned it over with valve cover off and spark plug out it did what it was supposed to as far as I could see. I put the spark plug back in and it turned over very slowly like it hydro locks on compression stroke. So now I’m stuck. It’s also like the exhaust valves are not opening. Any help would greatly be appreciated. Thanks in advance.
Morning. I love your vids! Thanks! I took my cam out to check it and I put it all back together. Now the machine idles really fast and it heats up real fast. I kept the chain and all where it was at. Any ideas? Thanks.
Glad i found your channel great videos. So today i thought id try to tackle the timing on my 96 sportsman 500 thanks to your video. I took the camshaft adapter cover off it has 3 bolts. I did all the timing stuff went to go out that cover back on and it wont go on that little needle piece sticks out to far now any ideas? I punched a hole innthe cover trying to screw the cover back on
You have to pull the cam out, turn it upside down so the decompression ball is out. the pin should slide back in. Make sure the spring is in the right spot.
Hi, how is life treating you? In one of your videos, you mentioned the blind plug that has to be removed in order to test for oil pressure, however, you failed to point out where the plug that must be removed is. I think that the thread is 1/8@ NPT and it must be the plug in the front of the cylinder head to the left of the exhaust outlet, but I also saw and larger blind plug to the right of the exhaust, do you know what that one is for? Take care, looking forward to your reply, in the meantime, I remain most cordially yours, Franklin
I got a 97 sportsman 500 and it sat for some years. But I took it out and cleaned it up. I had to replace the head gasket since there was water getting into the cylinder. I got that fixed and cleaned up the carb and tried starting it but I got nothing but a big backfire. I kept cranking it over and shooting some starting fluid in it but still nothing but some little pops once in a while. I watched this praying for it to be the cam but the cam and valve clearance was completely fine. And yes the timing was correct. Could you please help?
My 02 sportsman has lots of power but it is super hard to crank. I have to slowly pull the cord until it’s at TDC, then pull it to start. If i just pull hard first it will feel like it’s ripping my arm off. It’s just too strong for the electric starter…. Any suggestions can help
Thanks for very useful video! I am curious though, is the camshaft not restricted in the axial direction at all? The rocker shaft has an indexing bolt to keep it from sliding out the sides but the camshaft seems to just float around in its bearing holes, only held in place by the timing gear(!!)
I had noticed that too and wondered if they built it that way for wear reasons. The end of the cam has a flange to stop it from going into the timing chain cover. But the only thing stopping it from going the other direction is the lob.
Awesome video, just picked a 2003 sportsman 500, I'm thinking this is my issues as well, carb spits n sputters, dies when you start to accelerate, back fires, new carb, new sparkplug, switch on accelerator bypassed, do you have part # for cam?
Great vid! But, I'm feeling a little foolish, by not checking out more things before going for the cam replacement. My 2002 with 2800 miles had all the symptoms of the worn cam. However, when I popped the cover and got a look at it, it doesn't look worn down at all. Everything looks good, other than I can not find any white timing marks through the inspection hole, even at TDC. Chance it is just a timing issue? Has always started and ran great. Was plowing with it, it back fired and quit. It restarted and I limped it into the garage. Will start and idle fine, indefinitely. But any throttle will kill it. Thanks
Thanks for the good info! I am wanting to get a good Service Manuel for a 2001 Polaris Sportman 500 HO. Is there any one that you recommend? I am working on a top end rebuild/ inspection. Thanks
Hey buddy thank u for the videos. They are helping... so my sportsman 400 4x4 is starting right up great idle but when I give it has and hold the throttle open ot starts to bog out. So I was wandering which one of the 3 should I do first? The CDI Box or the Cam or the carburetor?
I would start with the carb first. easy fix first. clean the jets. from there check the timing and valve lash as it should be adjusted every year. The chain does stretch over time. then you can peek down and see if the middle cam lobe is worn out.
I know this is an older video but I am catching up on a lot of yours. I have a 2008 Sportsman 500 EFI HO X2. My compression relief is not working . I have to ease the pull start slowly til it is just past the ball on the cam . It starts every time then. Have you ever tried to fix the spring on the end of the cam for the compression relief ? I saw a video on youtube where it has been done . Great videos for the 500 by the way. I am learning a lot from you .
Where did you buy the new cam - i have a 1998 Polaris Sportsman 500 4x4 and need a good cam replacment kit? thank you in advance - Your videos are quite helpfull so thank you for doing them its appriciated highly by back yard mechanics like me.
Thanks for the video. You have helped me a lot with my 2002 sportsman 400 4 stroke. The bolts on my rocker arms are tight, really tight. Before I try more than a persuader. Is this a sign of something else? Warped top end? Should I heat the bolts?
Is there play between the rockers and valve's? You might not be at top dead center check down the plug hole to see where the piston is sitting. They usually are not that tight unless pressure is on them.
@@TitaniummanGarage As best I can tell, I am at TDC. I can see the piston and put long stick to find highest point. The back side rockers(intake) has lots of play, way more than .006. The front has very little play. A leakdown test had air going through the carb into the box. I assume that is the intake valves. I am preparing to replace valves but can't get those bolts off..
Hey, thanks for the great video! Replaced my cam this morning and it’s running better, but still dies out when rpm’s are raised. Checked the fuel pump to make sure it’s getting enough fuel. That’s fine but still dies out. Any suggestions? Thanks in advance love the videos!
This is a good video, thanks for putting it out there. I had a question about inside the crank case. My 2001 Polaris Scrambler 500 dropped a valve, and I think a valve keeper+keeper pieces somehow went into the case. I bought another head to put on but I didn't want to mess up anything in the case with those pieces still laying in there. I just don't want to have to take the engine out and apart due to already spending a lot of time on it and sealing the clutch cover back on before. Any suggestions? Thanks.
Thank you for the video I have a 2007 800 efi sportsman and it has the same symptoms Do you recommend I change the camshaft on it as you mentioned only the 500s were having that problem Appreciate any advice
I have a video on a 700/800 engine build. I always thought those cams would hold up good till I ripped one apart. Had to replace it. Depends how many miles you have on it. Over 4000? Yeah...I'd replace it.
Hi..great videos..I'm about to put a new cam shaft in my 96 Polaris sportsman..is there a certain way u slide it in ? Is that little bearing on top or on the bottom when u put it in ? And should I bolt the gear on right away or should I do something else first...I cant find a video of anyone actually putting it all back together. Thanks for any help u can give me..Ed
No certain way. You can slide the cam back in and bolt it to the sprocket right away. Just make sure your at top dead center and your 2 marks on sprocket are up at the top like in the video.
Awesome video. I have a 2002 Polaris Ranger 500 4x4 and it has 600 hours I don’t know if 600 hours is high or low . Runs amazing but the gasket that connects to the cylinder and carburetor has a little leaks it dies when the motor is not warm and when I restart it I saw vapor or steam coming from that gasket only see the steam or vapor whatever it is when I restart it.
@@TitaniummanGarage I just ordered it the gasket. It is actually running rich. Use lots of gas and leaves black smoke on the end of the muffler and frame and goes to lots of gasoline not crazy but not good
@@MOUSEBOWEN That's interesting. But makes sense. Never seen that happen. You'll have gas vapors lingering in the carb boot. How much black smoke? It could be rich or your valves and or valve seals might need to be replaced if it's a lot of smoke. I had one that turned out to be a bad oil ring(the bottom ring) on the piston was bad. But your using a lot of gas so it wouldn't be that.
Matt S @Titaniumman Garage There is a 98 or 99 Polaris Sportsman 500 coming up at an auction. Owner said that it does not release compression and won't start unless you use a jump start, then starts and runs fine. He said that the cam shaft was replaced and then this no release of compression happened. I read there is some little spring with the ball that releases the valve on the exhaust side. Where is the spring, i didn't see it on the pics of the new parts on e-bay etc. Not sure what a great price would be for this machine. I guess it has about 3700 miles on it, is a 98 or 99.
Depending where you live, they sell for 1700 to 2200 clean and no issues. If your gonna keep it..it might be worth up to 1200. I try not to pay more than 800. Something that old will usually have other issues too.
Hey bro...just put everything back together after putting the cam shaft in...now it wont start..sounds like 8t wants to buy wont...before I replaced the cam it would start right up..do u know which straw in the tank that the reserve line goes on ? The tall one or short one ? I put it on the short one..I did replace the cam sprocket because that came with the kit...when I put the new one on I made sure the 2 dots were at the very top and I could see the T through the hole in the pull start case..not sure what I did wrong..if I didn't adjust the valves right would that cause it to not start ? I'm about to take my sledge hammer to it !
Short straw is reserve. Double check you have fuel going to carb. Shoot some starting fluid in carb. It helps. If rockers were not adjusted it would still fire. Check your electrical conection make sure you have spark.
just replaced the cam and rockers on a 97' Polaris sportsman 500. Is there torque specs for the 4 rocker bolts and 3 bolts on the timing chain sprocket? I did see the valve lash was .oo6.....just dont want to break somethin or have them to loose and they come out.
Great videos. Very informative! Do you answer questions about problems ? I have a 2004 700 twin with a carburetor. I try do all my own fixes, but I always end up with questions. I search your videos first.
Great!! I replaced the radiator, fan switch, temp switch, thermostat, throttle cable, and the boot between carb and intake. I had recently put new plugs, new carburetor, new air filter, new fuel pump. It ran well but sputtered at mid throttle ( boot was busted). When I noticed I had an overheating problem, I replaced the parts I mentioned first. Put it all back together and it rough idles terribly. Doesn’t respond to easing on the throttle ( tries to shut off) Mid throttle and full throttle it runs well but back fires terribly when you let off throttle. I continuously have to adjust the throttle screw to maintain 1190 to 1250 rpm’s. I am clueless at this point. Like I say , it ran fine before finding the issues. ?? Any ideas? Someone said I needed to fine tune the pilot screw..??
@@chadwilliamson-cn6wn I just had one like that I wanted to set on fire because I was pulling my hair out trying to figure it out. It just so happened I bought a 600 and a extra carb came with it. I cleaned mine 3 times. Your on the right track with the fuel mixture screw. I even tried an aftermarket carb. No success. I put the oem 600 carb on. It ran perfectly. I had 2 700s. I had the same issue there as well. I robbed the carb from one and put it on the other. Same outcome. I haven't been able to figure out why one carb worked and the other didn't except that maybe the carb needs to be dipped to clean it well enough on the inside. I know that's not much help. But that's what I experienced.
@@chadwilliamson-cn6wnAlso keep in mind a backfire is a lean condition. It can mess things up as well. The 600 I told you about backfired because the fuel mixture screw was set wrong by the previous owner. When that happened it did 2 things. It fouled out the plugs. It wouldn't start after. If you were turning the key when it backfired you could shear a flywheel key off. I checked my flywheel and one magnet flew off. Messed up the stator.
@@TitaniummanGarage Good afternoon sir. I have the opportunity to work on my 700 today. I have removed the carb once again and finally located the pilot screw. (?) Located on the bowl of the carburetor, up inside of a hole that you can’t get to without taking carb off and turning upside down. The screw was tightened all the way in.?? I was told by a friend of mine that it should be turned at least 1 1/2 turns out from tight. Is this correct?
Thanks for the video, I’m going to replace the head gasket on on my 06 800 X2, that being said , can I just remove the valve cover gasket, put the engine at TDC, remove the cam gear and tensioner only, then unbolt the head according to your video and then reverse , or am I missing something?
@@TitaniummanGarage hi so I have a 02 Sportsman 500 h.o. all the camps listed on Amazon say 500 all models do you think it's the right cam if it doesn't say ho listed I just don't want to get the wrong kit thanks
I just had my carb rebuilt on my 02 sportsman 500 ho. The Chinese one I had worked, but when it got hot it seemed to be rich (or lean) and stalled out. When I put on the original rebuilt carb it started and idled well but when I give it throttle it coughs and sputters and I have minimum power . I'm not sure why this is happening now with the original rebuilt carb, but it is. I thought for sure it had to be a carb issue, but some are saying now that it could be a cam lobe issue. That doesn't make sense to me as that should have presented itself in my mind before the carb change. Any insight is appreciated. Thanks
Hey I'm tackling this project right now I got it for really cheap. but when I took the cover off it was missing rockers and everything. I bought the rockers but didn't come with the 4 bolts to bolt it down. I orderd them with what I thought was the part number but bolts are way too long. Do you have a part number or the size of the bolts. The ones they sent me are to big and too long
Is there marks on chain also for setting timing aand how much time was this cam job.Thanks in advance good stuff and was wondering how to adjust timing here if it is off and what might be the symptoms here.Sorry for all the questions
No problem. There are no marks on the chain. But..the links are silver. If you take the chain off, set the crank where the mark is on the case. Oh..that wasn't in the video. Take the stator off. The gear the chain rides on has a mark. Line it up with the mark on the case. Put your chain on. Sliver link at timing mark. The other 2 sliver links will be at the top of chain where the cam goes. Line those up with cam. Detents. And boom. Perfect timing. Check out my video on splitting case sides. You'll see what I mean..
Is there a decompression release any where on the cam . My 500 does not turn over when trying to start. With my limited knowledge I have checked timing and valve clearance (.006). Motor turns freely when spark plug is removed. I am missing something.Thanks Jon
I have a 2000 Sportsman that sat for 3 years with old fuel, rebuilt the carb but found a faulty fuel pump also. No spitting through carb but bogs at higher speeds. Waiting on fuel pump to show up. This has 1700 miles on it, what is the average mileage for cam wear? Thanks for the informative video.
You have a 2000 so you should be good. 1998 and 99 were the bad cam years. Polaris made them too soft. I can't tell you the average mileage. It depends on how hard it was rode.
I bought the one on the video off of ebay. Don't know the brand. I didn't care for the rockers that came with it. I now buy slightly used cams in tolerance. I like to stay all Polaris.
The decompression ball rides on a small shaft and at the end it has a weight. It acts on cyintrifical motion. As the weight spins it closes the decompression ball. The spring holds it open at start up. Or should I say out.
What year is this? I have what I believe to be either a 99 or a 2001 Sportsman 500 in the realtree camo pattern. I'm trying to find the VIN but am brand new to ATV repairs and what not so I haven't been able to find the any numbers on mine yet.
@@TitaniummanGarage Thank you, ill give it a look this afternoon and see what I can see. I'm pretty sure its not there which has me wondering some more about this quad.
@@LNRRidez What about the sticker on the hood by the front rack. It should say the number there too. I forgot what year they stopped doing that. I want to say year 2000. not sure.
I have a 01 bigboss6x6. My shifter bracket is really in the way of the cam sprocket. On yours its open there. Mine is factory welden in the frame. Seems the engine in that 500 is furter back in the frame than in my Bigb500
@@TitaniummanGarage yeah. Gonna atleast try with the engine still mounted 😜 thansk for answer. A tip for you is do a drivechain tension video on a 6x6 . Is none on RU-vid. //Sweden
I got the one in the video off ebay. I didn't like the rockers that came with it. That was 2 years ago. They may have got better now. I buy used camshafts and rockers in good shape within mechanical limits.
what were the symptoms If I may ask .I have a 01 500 and im having issues with power at wot just hesitates before it goes and sometimes a good 10 seconds of motor sounds kinda buzzy and almost stumbling and I rebuilt carb and put new fuel pump same crap any help would be greatly appreciated
Mine would only do about 5mph. I would open the throttle and it would stumble, like yours and die. No power at all. I just posted a new video. Check your cdi box too.
Check the stator and pickup coil. You said it's buzzy. Something might be rubbing by the stator. If you broke a started rope you might have knocked pickup or pulse coil out of alignment.
Sometimes I do to get an accurate timing mark. there is one on the gear behind the flywheel and stator. Lines up on the case. Its more accurate than the flywheel mark. The magnet on the flywheel try's to turn it as you set it sometimes.
so when you mention the 3rd way to check tdc with the screw driver .the piston should be at its highest point correct .I wish you were in rochester, ny maybe not I might be more of a pain in the butt and thanks again.I will tell my friends of your channel
So I have a polaris magnum 425 4x4 starts right up can Rev up with air box off but when I put air box on it won't Rev up has new air filter new fuel pump new fuel filter and new carb
The 425s and magnums are known for that. I would check for any air leaks. Intake boot, boot going to airbox. I've heard of guys drilling holes in the airbox. I don't think I would do that.
I know this vid is 4 years old but is there a recommended kit for this fix? I've been searching around and I've found anywhere from $63 on Amazon (from china) all the way to about $800, polaris OEM buying part by part. Quite a few on Amazon but the reviews are what I'm going off of and many are not within tolerance and don't fit properly. If you have a good recommendation it would be greatly appreciated.
Are you just talking about the cam? Or the gasket too? I buy used camshafts on Ebay. Like you said. the aftermarket is off. I buy Polaris head gaskets for 50 bucks on Ebay as well. So it cost me about 100 bucks.
@TitaniummanGarage thank you for that info. I was asking about a cam/rocker/gasket kit. I know Rev6 has a kit, but $250 isn't what I was expecting to spend, but most of the time, you get what you pay for.
@@corbinashley6857 Rev 6 Is really good. I've bought some crankshafts from them. they are top of the line. But if your on a budget, Ebay...Used parts. Just make sure the cam is in tolerance.
If you did that and shot a little starting fluid in the carb, it should fire up. I guess run down everything you took apart. did you bump kill switch? I've done that already. Its hard to tell ya without looking at it.
@@sorehair7075 No, I'm sorry I don't. Just check out e bay and do a little research on the part. It should be better than stock. Or buy a used one in great shape. I have done that twice already.
@@TitaniummanGarage Ok. I didn't know if it was possible to attach the cam and gear together in the wrong position or not. I didn't remember seeing any info on that in the video. Or is there something that only allows them to be bolted together in one position?
Check the adjustment on the choke cable by the carb. Loosen nut and adjust. Also the choke in the carb could be wore out. I've had that happen already. The spring too.
Just put a new camshaft in it. Started right up idles fine. But when I put it in gear and give it some gas on the throttle it is bogging bad and I hear popping coming from the front of the exhaust. Did .006 on the valve lash. Do you know what could be the problem???
Titaniumman Garage Ok thank you so much. I think this is the problem because when you put it on half choke it goes good but when you don’t choke it spits and sputters
Mine wont start now after putting in came, and new rockers, ajusted them, is there 2 strokes to tdc or just one rotation, i had my marks, wired up my chain gear chain never moved, cam only goes in one way, ive went back over it, popped once, just turns over, did yours fire everytime you replaced it or did you have any no start problems, maybe you can help and give me some feedback, im stumped
Ok guys, I'm in need of some assistance. 97 polaris sportsman 500, starts idles and runs decent until a little bit past 1/2 throttle then it begins spitting and sputtering. I have cleaned carb out, replaced fuel pump, changed spark plug. I have adjusted the air screw in the carb out to the point that it worries me (6 turns out). It seems to get a little better but problem still persist. I have a complete rebuild for the carb at the house to do. I am thinking of ordering a coil just for process of elimination. Do you suppose that it could be the cam and rockers, not opening the exhaust port all the way to let the exhaust out. Any advice will be greatly appreciated. Thanks in advance.
Rebuild the carb. Take the rocker cover off and look if the cam is warn. 6 turns is a lot. Sounds like a timing issue. But try the carb rebuild first. Have you checked your hoses and carb boot to see if there are any cracks anywhere?
@@TitaniummanGarage sorry new gas hoses, boots seem fine. I will have to check the rockers and cam tomorrow when I am off work. I will check timing as well after watching the cam replacement I kinda hope it is that now that I know there is a problem with the stock cam.
@@adamtucker8330 depends how far the cam is worn. I had one that would idle fine, but once I got up to 5 miles per hour or so it would shudder and sound like it would die. And a slight backfire.
Ok...I washed the quad before putting the gas tank back on...I just checked the spark plug and it was all wet under the cap...I pulled the plug and the whole plug was wet from the water...
Olá, sou do Brasil estou precisando comprar o kit, pode me recomendar uma loja, Eixo de comando para quadriciclo sportsman 500, 2x4, 4x4, eixo de comando, braço do balancim, kit 96 ~ 12, eixo de comando
1999 500 sportsman, I replaced cam shaft, exhaust lobe was gone. Now it pulls super hard and I have broke 3 recoils, starter doesn’t rollover fast enough to start. I can start it jumping is with a 20volt DeWalt battery and runs well when running until tonight. It first randomly engaged the recoil while riding and tore the rope. Kept riding, and 5 minutes later it backfired and quit. I was thinking I might have the cam in wrong. I put lobes down with everything at top dead center. Any suggestions?
The decompression ball might be stiff or the spring not right at the end of the cam. What cam did you use? When the sportsmans get old like this one they need a strong good battery. The wiring gets corroded and sometimes bad grounds. Not enough voltage to everything. Can't buy cheap ones. I buy Duracell, they are stronger but cost 30 bucks more. Are you buying the aftermarket pull starts? I bought 3 and they all broke with a stiff cam like your saying. Just make sure to check your flywheel that there aren't any metal parts from the pull start. I lost track of how many times I found broken springs in the magnets. Also...A quick trick if you can't find the issue. Use the pull rope and pull it slow till you feel it tight. thats the decompression ball in the cam. slowly pull past that part and hit the start button with a charged battery. it should turn over.
@@TitaniummanGarage Thanks for the quick reply! I ordered a good one from Rev6 that is closest to OEM I could find. I had the spring on the end wrong originally but fixed it. I probably have to take the cover off again and see if the ball is moving up and down like it should be. Battery is new and a good one. I have even tried jumping it with two batteries with no luck. I could pull start it "one pull" every time to start until I broke OEM recoil. Yes I am buying the aftermarket $40-60 recoils (junk). I just opened the recoil and the rope wrapped around the flywheel taking out the stator pickup pulsar coil. SO ordering a new one of those too. At the end of the day all these problems are coming from the Decompression ball. I have seen this issue posted on FB several times after replacing the Cam. I think someone put a cheapo cam in before selling it to the guy I bought it from.
@@3jdembows I have heard good things about them. Let me know how it goes. I haven't bought a aftermarket cam in a long time. When they first came out I had tje same issue you did and the rockers were too tight. I use used cams that are still in mechanical limits.
