Polaris 500 4x4 Has No Spark (Nobody Could Figure This Out)

[@HowardBailey1983]

Hey, just wanted to say thank you. I lost spark on a 500 just like that, and your video was the first that came up in the search, after watching I started with the cover and sure enough the thing was bent out away from the flywheel. I tapped it back in, put everything back, and first crank it started up. You saved me a lot of time running through everything. Thanks.

[@briancrull8678]

Taking apart an old Polaris quad makes you realize why stuff gets so neglected I spent 2 days washing and removing frozen hardware from “ needs a carb clean “ Nearly every system was compromised except the cooling .

[@NTK_FabWorks]

Here to say thank you for this video. Went riding last week, shut mine off in the middle of nowhere, 10 mins later it wont start. Luckily was with a buddy, he towed me the 3 miles home(of course both of us had our sons riding with us too). Smelled gas, put a spark tester on it, no spark but power at coil, bought new coil, waited 3 days, installed new coil and plug wire, still no spark. Googled, found this video, popped the cover off, sure enough pickup moved. Readjusted to .020" gap and boom, fired right up.

[@markhensley9378]

Always enjoy watching you diagnose and make repairs. Thanks for your time this weekend. Happy 4th of July weekend to you and your family.

[@scottthomson4561]

always watching yourvids from day one,,,i enjoy the obstacles you tackle to fix the problems ...DO WHAT YOU DO BEST,KEEP UP THE GOODV WORK,ALL THE BEST IN THE NEAR FUTURE,,KEEP IT UP,ALL THE BEST FROM THE HIGHLANDS IN SCOTLANS{UK}

[@coldbeerracing7401]

I worked on a Polaris that had the same hole worn in the clutch cover. He also had a plow. When the handle was pulled back it rested on the clutch cover and had enough weight to push it down enough for the pulley to hit and wear a hole

[@layton9950]

The older Polaris four wheelers seem to have a few weird designs some times. I think older four wheelers in general do.I have a newer sportsman and I can tell you they don’t have that problem with the over complicated removal of the gas tank(I’m sure you probably know that). Love my sportsman so far. It’s been very reliable and the most comfortable four wheeler I’ve ridden to date. I personally think their four wheel drive system is the best.

[@ghettsumm7949]

I noticed the boat bilge plug being used as a primary oil plug Haha,...... I did the same thing on my Harley. It works well. good vid sir.

[@matthewlavallee2251]

Never heat anything that has a grease fitting with a torch unless you remove the fitting. They like to become projectiles. Keep up the awesome work

[@odysseybeatz6694]

Been watching you for the past month, learned so much in that time span from just watching you’re videos, thanks!

[@thebigdustin]

the spark plug does actually spark a few times when you were testing for spark, you must have missed it, go back and watch. It sparks after you let off the start switch. residual energy in the coil maybe.

[@UnHoLyM40A3]

I was about to comment this

[@rm25088]

i noticed that too.

[@Yaboidkilla]

Man that snow plow mechanism is toast!

[@kenjohnson5498]

I have referred your channel to so many of my friends that are troubleshooting bikes and usually they can get there bikes running after a little hunting on your videos

[@jongeddes09]

I recently acquired a Polaris ATV of similar vintage and design. While it (for the most part) works now, these videos are great to see what's inside and what to expect if I need to disassemble and repair anything

[@bondvagabond42]

The holes on the back clutch cover get hogged out, then gravity pulls it down, then clutches/belts chew through those outer clutch covers. There is also supposed to be a rubber gasket between the two, and since the outer cover is tapered, removing that gasket reduces clearance, that and kids standing on them like someone else said, hah. I like the old polaris quads, cause the old ones have lots of parts interchangeably, they are funky, but they stayed the same kind of funky for decades. The belt drives are also good for whacky swaps, im putting a 20hp yanmar sailboat motor i got for free into a trail boss 350l 4x4, and im helping the neighbor kid put a 540cc arctic cat sled motor in a trail blazer 250.

[@stevefritch3180]

Hey Joe! Another great video!! I really enjoy learning from your videos!! Someday when I can afford a four-wheeler or dirt bike, I will definitely go back through your videos and try to find a video that matches the repair that I will be doing. Thanks again Joe! P.S. I would try heating the bar for the plow and hitting it with a sledgehammer!! Lol.

[@seanchurchill9415]

How about a power bar for better leverage; )

[@jboy9724]

My bet is the clutch cover got worn down from a kid riding on the quad and putting their foot down on on the cover instead of the floor board. Super common in the CVT driven Polaris quads, a Dad wants to take his kid for a ride and that's the only place their feet land.

[@benjaminhess6997]

Before the year 2000 Polaris made them Thinner they get hot and warp really easy

[@supercooldude824]

Yeah because of inflation

[@johnDingoFoxVelocity]

They didn't just make it thinner they made it out of pot metal

[@nickero8432]

yep i used to do that as a kid

[@meandmybuddy964]

Or he has short gf lok

[@briancrull8678]

Swampy goodness under those clutch/ ignition covers …. Going to enjoy a Polaris video !

[@Fresh1O1O]

I would put a floor jack holding on the plow connector and then apply heat… so have it barely off the ground with the jack to have that constant pressure and see if the heat works.

[@johnjones4932]

I had a 2000 model sportsman 500 4x4 and for the most part it was a good fourwheeler. The biggest issue I had was the 4x4 acting up and the camshaft messing up. The 4x4 froze easy going through snow and sleet and mud and water wasnt good for it either and it always went out after a while. It seemed to had some other electrical issues from mud and water n stuff. But when it ran right it had a ton of power and the 4x4 work good when it worked. Love the clearance to.

[@leekarpinski4038]

Joe ......... wot a busy man . Loving all the content mate 👌

[@MRMechanicRC]

This one looked a little nasty lol. Still amazes me how in almost every video your able to resurrect another bike and save it from the scrapyard.

[@cuzican8675]

Apparently I need to start making KZbin videos of then, I just got done completely fixing up a absolute piece of junk Kawasaki bayou 220. It had just about every wire cut, and the engine had no oil in it at all.

[@wctyre49]

Sure glad to have found your channel , I have a 2004 , I bought when it was one year old in Fairbanks AK.,it has been a headache lately but it 20 years old now , I've had so much enjoyment the whole time I've owned it , lately I've had to replace axle boots , belt and starter lately , all suspension bushing , now I just have to replace the speedo because no 4 wheel drive ,then it will be great again , lucky for internet you don't have to pay those crazy dealer prices. I've never let anyone else use it so it's in good condition.

[@damiandelapp5490]

I have a 97 that my brother In-law sold me for $300 that he had been overheated due to a failed fan switch with 2100 miles on it unfortunately it had been generally neglected and abused, i put it up on a stand and went at it, re-ringed/head gasket, hose’s, fan switch, thermostat, drive belt, all bushings/ball joints, struts&shocks, battery, handle bars/grips, set cover, brakes/tires, CV boots, air cleaner and full service front to rear, Ive put close to 700 miles on it all up through the Sierras and to the deserts of the South West, its extremely reliable and stupid simple to work on, parts are plentiful and cheap! i think i have total of maybe $1700 in it.

[@ArniethePirate]

When in search for spark, always pull the starter cord instead of using the starter. That's my way of doing it with these things anyway. Not saying it's the right way but it's worked for me.

[@johnhicks9529]

A quick tip trick that plastic cover can use A thin sheet of aluminum platting drill four holes through the plastic& aluminum plate to use aluminum reviots in it. To stop the noise of the rattling sound it puts off. From the rubbing up against the plastic. From not being tightened up inside of the cover shroud.

[@chefboyardee885]

I have been all around these fourwheelers, my father has one, my brother has one and I just sold mine because once they start breaking, it never ends, cv axles, carburetors, starters, top ends, clutches,bendixes that grenades inside the cover and breaks pickup coils and miscellaneous things the bill adds up rather quickly anyways great video I am just tired of working on theses machines as i did two rebuilds and put many hours in mine. have a great day!

[@frankreinhardt441]

My dad has a 200 sportsman 500 ho, he has had it since new, has well over 15,000 miles on it and the only things to ever go bad was a CV axle and belts, and normal wear items, like plugs, batteries, tires, etc. It is all about maintenance. I do like my 2009 Yamaha Grizzly a lot better, been a really good machine as well, i have 4500 miles on it and the only thing i have had to replace has been a couple of batteries and a spark plug. Both are good machines but the Yamaha is definitely easier to work on.

[@brianperkins6121]

if you can get to it , Check the valve lash , and take a look at the center exhaust rocker on the cam for wear,, check the function of the compression release on the opposite end of the cam to see if its spring is returing it to its compression release position,

[@eugenesbackyardrepair4593]

I like the use of the boat drain plug in that stator cover. Looks like if it works then do it

[@huntjunky1]

#1 You don't need to remove the step to take off the clutch cover. #2 The starter IS engaging but the bendix messed up. #3 The clutch cover is not stopping the starter #4 There is a hole in the flywheel to access the pickup screw. #5 If you pulol the primary clutch you'll discover that the centrifugal arms are worn out and this results in the clutch hitting the cover. #6 Good call...running without battery is exacctly what happenned. Probably be "dash" indicator lamps burnt out also. #You need to make sure the coolant reservoir is filled to indicated. #7 Need new air box as mos of the retaining blts are broken out of plastic (bad design)

[@aidengoodman7402]

The belt rubbing on the clutch cover is something that commonly happens on those things. The belt over time gets loose and hits the cover on idle. My 335 did that but a new belt fixes it

[@JoseManuel-lj4dk]

My cousin had a similar problem with his Polaris 500 HO with the pick up coil I took it apart and found a washer inside and messed up the pick up coil so I went on eBay bought one for 25💵 and fixed, It great video...

[@OldGYouTube]

First high quality video showing all kinds of stuff on my wheeler. Thanks

[@prf54]

I like these too. A thousand is good money for this too. There are good trail riders too. Have fun. I like to use a small body hamer to get things lose. Instead of a nail hammer! Dont foget the easy rider gun pouch made out of plastic for the rifle. Paul

[@johnhicks9529]

Check the spark plug.& pick up coil.& coil& the stator to for broken off.,or burnt wires to Tom.

[@johnhicks9529]

You can scuff it up to flex glue seal the plate on with.& then pop the revoits through the plastic after its stuck on for 4 hours. Then. You can prime it.& spray pilaint the cover black again to.

[@MrATOMBOMB420]

That piece on the outside is the trigger coil the pickup coil is the one on the inside that creates the voltage the trigger coil triggers it to send the voltage

[@derekcorvese9001]

I got a little hack for you so if you don’t have spark you go and get a thin wire put that wire into another spark plug wire start that quad keep it running and put that wires to both end and while the other quad is running try starting that it always works for me

[@bighomieJ5X]

Let's see if there's a mouse nest in the air box 😂😂😂

[@kelvincampbell4401]

Are you going to clean all the rust etc off it and clean it up.

[@donaldhammii1713]

My 96 sportsman 500 rubs too it’s a manufacturers defect. A couple dealers told me that.

[@jurrebongers]

12:05 u see spark when u turn the ignition off 😅😂

[@did_that_hurt8387]

came to the comments to see if anyone else noticed that but only when he had original plug in

[@ggermany2123]

11:40 Here too.

[@cwitt483]

Those older polaris clutch covers do heat distort and start rubbing from excessive idling without ventilation on hot summer days. Both of mine have needed new covers and they no longer rub at all.

[@eugenesbackyardrepair4593]

Joe im betting that was belt slap that wore that hole not the clutch. Not a big polaris fan but when they run they got pretty good power. Great for hunting and adventure riding

[@EinarLerschen]

Hard working fellow! Im amazed of the paste you keep posting these videos.

[@johnhicks9529]

One more tip trick the bearing sleeves may need lightly greasing up again for smoothe spinning of the armacher shaft on both ends.

[@johnhicks9529]

Dollar General mixed nuts peel aluminum.,or chocolate covered peanuts cans are the same from there to. Their around $3.00 A can.& you get your piece of aluminum in the process for your fourwheeler to.

[@TheCuttingtorch]

water is the enemy of cvt clutches.. and the belt will slip and you go nowhere.. a new cover or patch up the old.. also just looks like the cheap plastic is oxidized on the headlite so that should polish out with a restore kit..

[@chadoakes8002]

I've had a couple of those Polaris Sportsman's like that I had some issues with the ones I've had but for the most part they were pretty good machines they're not too bad to work on especially if you get a repair manual crawler office a pretty good one pretty detail thank you for the great video hope all is well

[@barneybuckley2014]

Been beating up my 99 Sportsman 500 for 23 years plowing snow. Heavy plowing created enough heat from the clutch to warp the plastic clutch cover. Judicious application of heat gun and massaging away from the clutch would hold up for a few years.

[@andrewvanhalst9486]

A lot of times the front motor mount breaks free and allows the motor to twist and in turn, the clutch will hit and rub thru the clutch guard.

[@roynelson7613]

I remember you had one of these on your channel a few years ago it's crazy how they make certain things difficult to get to on these things but it sounds pretty damn good now bro ♥️👍🏽👍🏽👍🏽 happy early Force man ♥️😎👊🏽

[@bigcaputo09]

Once you said the starter was changed. That means someone was under the cover and messed with stuff. I knew it would be the pick up after that. I'm very surprised it still worked.

[@Scraps2010]

Plug looks good. Gap is a bit big. He says banging on the frame to close gap...... classic.

[@johnhicks9529]

It's the starting starter gear drive unit is either stuck.,or needs spray oil., gear lube on the gears.

[@frederickgiordiano2105]

Great electrical troubleshooting. I teach electrical technicians how to troubleshoot, and your logic was perfect (to use one of your favorite words).

[@chathamguy1able]

years and years ago i did not like polaris because of belt brive now just ablout all atv's are belt drive ----good find should make some money off of it --- keep up the good work

[@bkon4675]

Polaris makes a spark plug removal tool included in the tool pack. The gas tank doesn't need to be removed.

[@craig2963]

Before you beat the plow bar to death, remove the grease fitting to be sure that the grease can even get through it. The grease fittings seize up as well. Than when you heat it up again use a tea candle to rub on all the places that you can see that should turn. Use the candle like penetrating lube. Heat a joint and apply the candle, allow the candle wax to wick into the joint with the heat. It will surprise you how well it can get into the tight places.

[@RayFinkle]

Check the motor mounts. Mine wore through the belt cover because of that. Also get a MAPP gas tank instead of propane. More heat. :)

[@timseeds9381]

That cover needs to be sealed up . Either plastic weld it or get a new cover . If water gets in there the belt will slip for sure!

[@timseeds9381]

The cover for the belt is like that because some one was riding it with there foot on that cover I made that mistake on my 700 twin !

[@elainecarter22]

Great video. I have one with no spark. I’m gonna work on it soon. Thanks hope this is what’s wrong with mine. 1999 sportsman 500

[@seanchurchill9415]

Great video once again Joe. I do enjoy your take on things. You said something about it 'going through the gears'? It a 'CVT' belt automatic

[@gmarsh7873]

Well done how much you got to spend on it?

[@shartne]

It could be said the way that runs so good it does have low miles on it. After a lot of labor or yours it was worth the money. Soak that plow part in Vinegar to get it unfrozen.

[@peteraitken6494]

Not a bad 4x4 joe plenty power good job getting it going defo a good work horse I'm sure you will get the plow moving in time take bare mate 🔧🔧👍👌🔧

[@joshuarussell7546]

Love that area he takes the bikes to test ride them really like that house 🏠 really beautiful bro

[@letsrydeaz3126]

Just fixed one where the pull start Rope broke and a small piece got in between the flywheel and pick up and pushed the pick up out, gap was probably 1/4”.

[@billbidell238]

Thank you for the excellent video, very helpful for my 1997 Magnum 500 6x6 i picked up at an auction, look forward for more of your video on / fixing and bleeding the rear brakes

[@680blindreaper]

Great video Joe! Have a good fourth!

[@MrAdrenalin17]

Great deal n honestly very happy to see u try a quad out in the mud finally lol, would love to see more of you trying quads in mud

[@schfiftyfive9680]

Your 4x4 won't work if your speedo doesn't work. You have to go to the base of the cable and replace the little key that goes into the trans. That likes to shear off

[@eagle777dh]

The bolt you found might have come from pull start. Good job bringing another one back from the dead.

[@978twostrokegarage2]

Dam Joe you just keep bringing them back to life 💪🏻🤟🏻💪🏻

[@rockyjustus2829]

Backing plate that the cover bolts to is your culprit when you find issues with the cover the bolts either loose or missing and make sure the cover is in its groove with it's seal

[@bigbullhorn8443]

U should have a good Flooring mallet in your arsenal buddy. There heavy and really hard rubber for banging shit loose but won’t crush the steel either

[@troyaldridge3853]

it's rubbing because someone stood on it while it was running liky

[@kevinkay8115]

Seen the clutch cover issue before from young riders standing on cover instead of the footrest.

[@Frisky_FZR]

It’s 12 am but I’m here 😂 school tomorrow

[@UNEVEAGLE]

You don’t have holidays on summer months?

[@Eli-tg5xz]

Imagine going to summer school ha bozo 🤡

[@tonybason4929]

12 mins and 5 seconds it happens you get a spark when you turn the key to off. cheers for the vids keep em coming tony from Austfalia haha kididdin Australia

[@jjrara9198]

Those covers get nests in them, ridden without knowing. Then heat up and melt and distort, leading to rubbing. They need to design a inline screen to keep the mice out:))

[@exploringwithodin9682]

you have been getting pretty lucky latley

[@justinqasem4582]

Do a video oh how to get a striped oil bolt off a fourwheller plz

[@danielparsons3995]

The Polaris 500 sportsmen was the first quad I learned to ride, so much power and the 4x4 works great going up steep hills or wash sides, it's my favorite until I uncovered that clutch with a damn rubber belt... Wow that's a shitty design, my Honda 400ex is so much more mechanicly reliable I'm glad when I had a chance to buy a quad I picked my Honda 👌👍

[@levicarrol9401]

most quads have belts like that even outlanders and shit

[@wesleybartholomew5920]

you need to take the old grease fitting off and put a new one on and then try filling it with grease

[@jamescarey9197]

Don't know why, but my brother-in-law swears by his Polaris, but I'll stick with my Suzuki. Always enjoy your videos, alot of useful knowledge and tips👍

[@polesheddude]

They all break and a lot of it is due to lack of maintenance.

[@richardogle7772]

You will probably use a full tank to torch that plow but it will free up eventually i had to torch mine for awhile but it freed up and works good now

[@jrx2662]

you buy all these atv's, snowmobiles, what do you do with them? do you sell them? are the cheap?

[@exploringwithodin9682]

im trying to get back into this rebuilding but everything is so expencive and projects around here are scarce

[@allensnook7760]

Was suprised you didnt try and melt a patch into that open wear hole,should be easy enough with hot flat soldering iron n heat gun,just find some trash plastic parts and melt in or even stitch in worst case just put a piece of tin on inside and rivet from inside out pound outside stem flat ur golden.keep soaking n pounding the plow attachment it will eventaully move because it did at one time.just rust has its frozen hold on it.never give up!!!snookie pa.💥👍💥

[@edmarlborough733]

ANY time, ANY time you replace a toothed gear, count the teeth... One day it will pay off, maybe not for a long time, but one day it'll all be worth it. That 2-3 minutes could save HOURS later... You Sir do awesome work, my comment was for the guys just starting out on their journey as a tech. Sometimes just a mention of a no brainer helps...

[@nickero5804]

im so excited i just bought the same thing for 300 bucks!

[@shainexxxsescrimshaw7605]

That spark plug issue is the same for my lexmoto lxr 125 bike, the whole plastics and petrol tank has to come off, nightmare

[@johnhicks9529]

Yes their angled downward Tom. Only if their worn down.,chipped teeth should those be replaced.,or the contractor spring to release the starter gear drive from the flywheel to.

[@ronhanish]

put ur jack lift on seized part of plow. just lift real hi and heat also :)

[@sweatingbullets4235]

So watching what I saw I assume what happen was the pull cord guts came loose and slapped the pick up coil he goober snotted the cover back on and then found no spark to let you know the specs on the pick up coil is .4-1 mm from the magneto I try to set those to .621 on a feeler gauge or close to that I hope that helps someone out there good job on the find I enjoy deals like that

[@sweatingbullets4235]

As far as the lights check and see if your rectifier is charging the battery when they go the make the bulbs super bright for a while then die make sure you are getting around 14.4 volts if you are getting like 17 or nothing but the 12 volt that your battery has change the Rectifier

[@exploringwithodin9682]

morning awesome vids

[@rickfaulkner9027]

Slant on starter gear lets gear mesh smoother

[@JustinHolloway307]

I love my old sportsman 500 green as well I also like my 335 is awesome too

[@trose7620]

It's engaging. Sounds like a 500. Check spark.