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Posted: 11/15/2014 5:16:36 PM EDT
Hey guys,
So I have a buddy who has a 01 polaris. His ex wife sugared the tank and he drove it around until the system gummed up (he didn't realize what had happened till it was too late). The Polaris guys steamed cleaned it numerous times and put a carb kit in it. After that it ran ok.This was a year or so ago. This summer he asked me to look at it as it was spitting & spuddering/coughing. The air filter was soaked in fuel and there was a bunch of fuel in the air cleaner box. I changed the oil, installed a carb kit and new air filter. I did look in the tank and everything looked great. No buildup or gunk anywhere. He has been riding it ever since and says it ran like a champ. Fast forward to today. He calls me and said it is doing the spit/spuddering again. He was elk hunting and riding it down the road when it started happening so he turned around and parked it. I asked him if there was fuel in the air box and he said he didnt look. So he is bringing it by tomorrow for me to look at again. First thing I am going to look at is fuel in the air box but if it was a carb issue. If it is, why would it take so long to pop up? Could there be residual crud in the tank that is causing the carb to gunk up? Anything else it could be??? Could it be a jetting issue at high elevation? |
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This is the kit we used LINK
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What kind of fuel lines does it have?
if it has the grey ones they will turn to a gummy substance that will cause all kinds of issues.
if they are the black rubber you should change them out if they have not been changed in a while. |
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something I forgot to ask, how often does he ride it? if not very often he needs to shut the fuel off to the carb when ever he is finished riding. fuel sitting in the carb will go bad and gum it up too.
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Flat cam on the PO PO real common I assume it is a 500 ho ????.
It is a easy fix once verified to be a Cam Issue. |
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Flat cam on the PO PO real common I assume it is a 500 ho ????. It is a easy fix once verified to be a Cam Issue. View Quote Yes it is a 500ho. I'll have to Google flat cam as I am not aware of it. I have it in the shop now. I had to use a battery charger to get it to start. Once it is warmed up it seems to Rev up with no issues. If you flog it and let off the throttle and flog it again, it does pop/spit a little. |
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What kind of fuel lines does it have? if it has the grey ones they will turn to a gummy substance that will cause all kinds of issues. if they are the black rubber you should change them out if they have not been changed in a while. View Quote This, I had a split line on our Sportsman 700 give me all kinds of headaches until I found it Sputtering, dying on anything more than half throttle. Rebuilt the carb, ended up being a vacuum line to the fuel pump with a small crack. |
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Ok so I read about the flat cams. I removed the valve cover and while turning the machine over, I can see the exhaust and intake valves moving.
After reading the bad cam threads, guys were experiencing bad backfiring. Their cams looked super worn down. How can I tell if mine is worn enough to replace? I hate to just start throwing parts at this thing. Thanks |
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Here is a video link to the cam and valve train.
http://s174.photobucket.com/user/chevy_sb350/media/20141117_132039_001_zpsuointy4m.mp4.html |
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Ok. So while I was putting the valve cover back on I grabbed the sparkplug wire and boot. When I gave it a light tug the wire came right out of the boot. It was loose. Wonder if this is the problem?
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Ok. So while I was putting the valve cover back on I grabbed the sparkplug wire and boot. When I gave it a light tug the wire came right out of the boot. It was loose. Wonder if this is the problem? If it wasn't before, it is now Lol. True. I trimmed the insulation back to expose the wire. Turns out these are a thread on boot, so I threaded it back on. Reinstalled the fuel tank and fired it up. With no air filter it pops and spits but if you install the air filter and put the air box cover on, it runs awesome. |
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Anyone have any other suggestions? Comments on the cam before I button the front end back up?
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Quoted: Lol. True. I trimmed the insulation back to expose the wire. Turns out these are a thread on boot, so I threaded it back on. Reinstalled the fuel tank and fired it up. With no air filter it pops and spits but if you install the air filter and put the air box cover on, it runs awesome. View Quote View All Quotes View All Quotes Quoted: Quoted: Quoted: Ok. So while I was putting the valve cover back on I grabbed the sparkplug wire and boot. When I gave it a light tug the wire came right out of the boot. It was loose. Wonder if this is the problem? If it wasn't before, it is now Lol. True. I trimmed the insulation back to expose the wire. Turns out these are a thread on boot, so I threaded it back on. Reinstalled the fuel tank and fired it up. With no air filter it pops and spits but if you install the air filter and put the air box cover on, it runs awesome. IMO that would point me to believe it may be an air fuel mixture ratio on the carb. the air filter is causing enough of a air restriction to get the A/F mixture close to being right. |
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did you check the valve clearance while you were in there? View Quote View All Quotes View All Quotes Quoted:
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Anyone have any other suggestions? Comments on the cam before I button the front end back up? did you check the valve clearance while you were in there? No, ive never done that before. Ill have to look that up |
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No, ive never done that before. Ill have to look that up View Quote View All Quotes View All Quotes Quoted:
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Anyone have any other suggestions? Comments on the cam before I button the front end back up? did you check the valve clearance while you were in there? No, ive never done that before. Ill have to look that up If it is a 2001 with unknown hours/miles on it. I will BET that may be the cause or a big part of his running issues. Cold out of adjustment valves will wreak havoc, more, but close, as will warm valves. Just for giggles, do you understand how the valves work? In other words, how they play a part in the running and performance of an engine? |
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I know how an engine works. I just have never adjusted valves before.
I did find a video on YouTube. I'll watch it when I get a few mins. |
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I know how an engine works. I just have never adjusted valves before. I did find a video on YouTube. I'll watch it when I get a few mins. View Quote my intent was not to come across as a smart ass.....sorry if that is what was implied. Out of whack valves will give the same symptoms as a fubar fuel system. I am not sure what valve system that thing has, but if it involves a bucket, it s more work, tapets are very simple. |
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No, your fine.
I found a how too video on youtube. I'll look at it tomorrow and see if I can get them checked. |
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I watched the video. Top dead center on the motor and adjust the valves to .006. Ill get it done today.
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Ok. Used this link and found the t in the inspection hole. I loosened the nut on top of the intake valves and I had to loosen the screw multiple turns before the feeler gauge would fit. I'm guessing 3 or 4 turns.
Seems way off. |
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Strike that. Didn't have the 2 dots on the cam facing upward. Move and readjusted.
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So it was the Tapet style.....good.. button it up and report back View Quote View All Quotes View All Quotes Quoted:
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Strike that. Didn't have the 2 dots on the cam facing upward. Move and readjusted. So it was the Tapet style.....good.. button it up and report back Ok, got it buttoned up. It started right up. Idles good and only has a slight hesitation when you go from idle to full throttle. If you ease into it there is no hesitation. Also, there is no popping or spitting. I also found a loose ground wire that goes from the motor to the chassis. I got that really crimped and soldered. I am waiting on a drive belt before I test ride it. The onld one was marginal. |
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Ok, got it buttoned up. It started right up. Idles good and only has a slight hesitation when you go from idle to full throttle. If you ease into it there is no hesitation. Also, there is no popping or spitting. I also found a loose ground wire that goes from the motor to the chassis. I got that really crimped and soldered. I am waiting on a drive belt before I test ride it. The onld one was marginal. View Quote View All Quotes View All Quotes Quoted:
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Strike that. Didn't have the 2 dots on the cam facing upward. Move and readjusted. So it was the Tapet style.....good.. button it up and report back Ok, got it buttoned up. It started right up. Idles good and only has a slight hesitation when you go from idle to full throttle. If you ease into it there is no hesitation. Also, there is no popping or spitting. I also found a loose ground wire that goes from the motor to the chassis. I got that really crimped and soldered. I am waiting on a drive belt before I test ride it. The onld one was marginal. Good deal on the starting right up. As for the above, is this a single carb or something else? If it is a single, it sounds like the air mix screw is out of whack....just slightly. GENERALLY, the air mix is from 1.50 turns to 2.5. IIRC MT is about 3-4k feel on most of the flat spots. I would set it at 2 turns out and go 1/4 turn in either direction until it is GTG. Only drawy back is if you live near the babnanna belt, turning that screw will become SOP. All of my carb'ed bikes have done very well @ 2.25 turns out up to about 6500'..... highest peak on the east coast was about.....7500'. MY experience a well tuned carb (sea level settings) will do pretty damned good up to 8000' or slightly less. You got any pix of this contraption? |
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Hey I just got back in to this thread. Polaris 500 has to have the air box lid on it to run properly IT WILL NOT RUN FOR SHIT WITH OUT IT hence the popping and sputtering you get with the lid off. It does not matter if you have a air filter on the intake or not it has to have the lid on it..
As for the bad cam if you roll the engine over you will see the galling and the trashed rocker arms and cam lobes if that is not the case you maybe lucky. Pm your # I can call you and help Via The phone. Spent may hours with Polaris, Lots of tricks on them guys Plus I built them for 10 years. Owned many of them One damn tuff machine. Jaime |
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Hey I just got back in to this thread. Polaris 500 has to have the air box lid on it to run properly IT WILL NOT RUN FOR SHIT WITH OUT IT hence the popping and sputtering you get with the lid off. It does not matter if you have a air filter on the intake or not it has to have the lid on it.. As for the bad cam if you roll the engine over you will see the galling and the trashed rocker arms and cam lobes if that is not the case you maybe lucky. Pm your # I can call you and help Via The phone. Spent may hours with Polaris, Lots of tricks on them guys Plus I built them for 10 years. Owned many of them One damn tuff machine. Jaime View Quote Thanks for the info Jaime. I am waiting on a drive belt before I can put it back together. After that, I can get it out and ride it. If I have issues after that, Ill get a hold of you. Appreciate the help! |
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Drive belt showed up this afternoon. I got the 4 wheeler all put back together and took it for a spin. It ran like a champ. No hesitation, just smooth.
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Drive belt showed up this afternoon. I got the 4 wheeler all put back together and took it for a spin. It ran like a champ. No hesitation, just smooth. View Quote Yeah, well, gues what, ya bastage. Mine Sprint is getting a new engine and it is all YOUR fault! (P.S. What part of the Fantastic State of Montana do you live in?) One of these days I WILL live in the Babnanna Belt |
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Yeah, well, gues what, ya bastage. Mine Sprint is getting a new engine and it is all YOUR fault! (P.S. What part of the Fantastic State of Montana do you live in?) One of these days I WILL live in the Babnanna Belt View Quote View All Quotes View All Quotes Quoted:
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Drive belt showed up this afternoon. I got the 4 wheeler all put back together and took it for a spin. It ran like a champ. No hesitation, just smooth. Yeah, well, gues what, ya bastage. Mine Sprint is getting a new engine and it is all YOUR fault! (P.S. What part of the Fantastic State of Montana do you live in?) One of these days I WILL live in the Babnanna Belt New engine hunh? How much is that running you? I live in south central MT. Billings to be exact. Not born here but grew up here since I was 1. Ill never leave. |
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New engine hunh? How much is that running you? I live in south central MT. Billings to be exact. Not born here but grew up here since I was 1. Ill never leave. View Quote View All Quotes View All Quotes Quoted:
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Drive belt showed up this afternoon. I got the 4 wheeler all put back together and took it for a spin. It ran like a champ. No hesitation, just smooth. Yeah, well, gues what, ya bastage. Mine Sprint is getting a new engine and it is all YOUR fault! (P.S. What part of the Fantastic State of Montana do you live in?) One of these days I WILL live in the Babnanna Belt New engine hunh? How much is that running you? I live in south central MT. Billings to be exact. Not born here but grew up here since I was 1. Ill never leave. $1,077 Complete engine, minus stator and stator cover. Boutght those too, so by the time I drive to Dallas and back to houston, about $1400. I would part the bike out, if I did not know how to turn a wrench. it would be close to 3K to have someone else to the work. Once I get that motor in, I will tear the other one down (broke sparkplug), and do a complete overhaul. See what is close to out of spec, and stuff i KNOW will need replacing. Rings, Head gasket will beed to be done anyways once the head comes off, going to put a different 6th gear in it. Not going to do any performance mods......no need to, the sumbitch goes 160mph anyways Fast i have seen (GPS) is 159.8mph. Between the two motors, I shoudl get 1/4 million miles out of it |
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Quoted: Yes it is a 500ho. I'll have to Google flat cam as I am not aware of it. I have it in the shop now. I had to use a battery charger to get it to start. Once it is warmed up it seems to Rev up with no issues. If you flog it and let off the throttle and flog it again, it does pop/spit a little. View Quote View All Quotes View All Quotes Quoted: Quoted: Flat cam on the PO PO real common I assume it is a 500 ho ????. It is a easy fix once verified to be a Cam Issue. Yes it is a 500ho. I'll have to Google flat cam as I am not aware of it. I have it in the shop now. I had to use a battery charger to get it to start. Once it is warmed up it seems to Rev up with no issues. If you flog it and let off the throttle and flog it again, it does pop/spit a little. |
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$1,077 Complete engine, minus stator and stator cover. Boutght those too, so by the time I drive to Dallas and back to houston, about $1400. I would part the bike out, if I did not know how to turn a wrench. it would be close to 3K to have someone else to the work. Once I get that motor in, I will tear the other one down (broke sparkplug), and do a complete overhaul. See what is close to out of spec, and stuff i KNOW will need replacing. Rings, Head gasket will beed to be done anyways once the head comes off, going to put a different 6th gear in it. Not going to do any performance mods......no need to, the sumbitch goes 160mph anyways Fast i have seen (GPS) is 159.8mph. Between the two motors, I shoudl get 1/4 million miles out of it View Quote View All Quotes View All Quotes Quoted:
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Drive belt showed up this afternoon. I got the 4 wheeler all put back together and took it for a spin. It ran like a champ. No hesitation, just smooth. Yeah, well, gues what, ya bastage. Mine Sprint is getting a new engine and it is all YOUR fault! (P.S. What part of the Fantastic State of Montana do you live in?) One of these days I WILL live in the Babnanna Belt New engine hunh? How much is that running you? I live in south central MT. Billings to be exact. Not born here but grew up here since I was 1. Ill never leave. $1,077 Complete engine, minus stator and stator cover. Boutght those too, so by the time I drive to Dallas and back to houston, about $1400. I would part the bike out, if I did not know how to turn a wrench. it would be close to 3K to have someone else to the work. Once I get that motor in, I will tear the other one down (broke sparkplug), and do a complete overhaul. See what is close to out of spec, and stuff i KNOW will need replacing. Rings, Head gasket will beed to be done anyways once the head comes off, going to put a different 6th gear in it. Not going to do any performance mods......no need to, the sumbitch goes 160mph anyways Fast i have seen (GPS) is 159.8mph. Between the two motors, I shoudl get 1/4 million miles out of it Damn. Sometimes I hate having the knowledge of fixing things as I make a ton of work for myself! I have projects all over the house. |
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Mine was doing exactly this and I fucked with a long time certain it was fuel related. It was a bad battery. Replaced it and it ran like a top. View Quote View All Quotes View All Quotes Quoted:
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Flat cam on the PO PO real common I assume it is a 500 ho ????. It is a easy fix once verified to be a Cam Issue. Yes it is a 500ho. I'll have to Google flat cam as I am not aware of it. I have it in the shop now. I had to use a battery charger to get it to start. Once it is warmed up it seems to Rev up with no issues. If you flog it and let off the throttle and flog it again, it does pop/spit a little. Interesting. He has been complaining of a bad battery for a while now. It is less than 2 years old but it will die if left for a long time. I have tired searching for parasitic drains but ive come up with nothing. When I it on the battery maintainer, it charges with no issues. A load tester says its weak but still passes. |
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