How to tear down a 2004 Polaris Sportsman 500 COMPLETLY and rebuild it!

I'll show you how to take the plastics and gas tank off a Polaris Sportsman 500. And a easy way to pull the motor. Then rebuild it!

[@smallgaragehustle]

Great video on the rebuild. So many are unfamiliar with Polaris and overlook them. It’s pretty much all I do nowadays.

[@chasevollbrecht8085]

Well you just gave me some ideas and you allowed me to confirm my suspicion of the motor being one giant case with the gearbox or two separate pieces and now I can go find a quad that's got like 325 and then go swap it

[@shawncordeiro5078]

On you tube i was just listening to malcum isolated before i watched your 1st ever long video acdc rocks

[@ls2005019227]

Excellent video & enjoying the longer format! Thanks again!

[@RichardWells-ft6sf]

I was thinking the aftermarket 500 kit might bolt on the 99/00 sportsman 335. Then I realized that the 500 is water cooled. If it bolts on, I'd still have the rad,and all the plumbing to do. Just a piston is 260.00 for the 335!! Great work dude, these kids can break more than they fix....

[@brianmyers466]

Excellent job. Fixing to rebuild my 500 ho. Thank you for videos. Have a great day

[@JH-td9rb]

Nice! Keep the long videos, super informative!

[@roelanderson6466]

Love your videos. We have an 06 450 sportsman we’re trying to get running, can you suggest one of your videos that shows how to pull the motor in a bit more detail?

[@williamtoney2599]

What was the stopped up vent line you mentioned?

[@jimpiazza8637]

Great videos - just got a 2004 500 ho and putting it together. the plastics were not on and have a bunch of bolts. Is there any where to get a good look at what bolts are needed for the front rack and plastics - and the back rack and plastics as well? Thanks for the videos - well done !

[@TitaniummanGarage]

They have T 15 hex head on the back. The front might be the same or they are screws with a 3/8ths socket head on it.

[@user-zd4iq1pn8s]

Amazing video, I have a few questions so I have 96 Polaris 2 stroke 250 cc But my first question is when tuning the carburetor how many turns would you say you would have to do for the idle speed air screw and idle mixture air screw ? My second question is When I put the ATV in reverse it dies out what do you think could be causing that would it be a wires or a sensor? My last question is when driving in Ford my throttle gets stuck should I adjust the throttle cable I mean that's it for now but I would very much appreciate it

[@TitaniummanGarage]

I would replace the throttle cable. They stick by the oiler. The reason it dies in reverse is because of the over ride button needs to be pushed in or bypassed. I wanna say 2 to 2 and a half turns out on the air screw.

[@richardsoule278]

Another excellent video, just wondering what area you live in? am in the u.p.

[@TitaniummanGarage]

60 miles south of GreenBay Wi.

[@ManuelLabour]

Hey man, I am rebuilding a 95' Magnum 425 and some parts are really hard to find. Curious what you would have laying around. Great video as always.

[@TitaniummanGarage]

I don't have much. Wish I could help. What are you looking for?

[@ManuelLabour]

@TitaniummanGarage Thanks for the reply. Looking for a fuel tank mainly. Could also use a front rad access panel

[@ericwanner7966]

This might not be directly relevant but I’d like to see a video on the difference between having and working on a carbureted Sportsman 500 vs an EFI one. I have an 09 EFI and it works fine but I was just curious.

[@TitaniummanGarage]

The engines are the same. The timing chain tensioner was the only thing that changed over time. The EFI is fuel injected obviously. It has sensors, fuel pump and an injector. Polaris had a wiring issue with those. The wires are thin and break over time by the injector and sensors. But other than that I can put a motor from a 2001 and put it in a 2009 keeping all the electronics the same.

[@dillongates4520]

Hi i have a question i have 2001 polaris sportsman 500 ho blew the rings for sure im planning on doing topend rebuild and im wondering what oil should i run for break in should it have 5w50 ps4 full synthetic oil? And abother question how long do i have to do break in period before taking it to full rip

[@TitaniummanGarage]

I use 0W-40 synthetic. I don't buy the expensive Polaris brand. I Let it idle for 5 minutes to let the oil get through the whole engine and back in the reservoir. Shut it down, cool off. Then let it idle for another 5. I ride it half throttle for maybe 5 miles or so slowly going through the power range after. It's usually good after that.

[@cameronbrownify]

I'm curious about the head bolt torque sequence. First: is the 52ft/lb just what the end result should be around? It sounded like you torque down to 52 after you hit the 22 (but you skipped that in the video?) and then you back off by 2 quarter turns? and Second: You mention 2 half turns after the 11ft/lb, but I only noticed you did quarter turns (line only did a 90deg movement). Maybe I am misunderstanding the terms?

[@TitaniummanGarage]

When I edited the video I messed that part up. Its 1) 22 ft lbs 2)52 ft lbs 3) back off 180 degrees 4) back off another 180 5)Tighten11 ft lbs 6)turn a quarter turn 7)turn another quarter turn.

[@jacolbysnowden3876]

That should put it back at 52ft/Ib after step 7

[@fzxdf5]

I got a 01 sportsman 425 I converted to a 500, the new jug is 4mm longer and the old timing chain is too short any thoughts? Can you break it and a couple half links or is there a different chain I can use. The piston skirt really really scored the walls deeper than 0.030. So I got a new jug.

[@TitaniummanGarage]

That's interesting! That means the aftermarket is 4mm longer than a OEM jug.That would also mean less power. I'm not sure what to tell you. I've used OEM jugs. Never had that issue. Take the timing chain tensioner out. I would think there is enough play.install and reset it.

[@fzxdf5]

@@TitaniummanGarage with the tensioner removed it is still too tight. I can’t get the alignment post to align on the cam shaft. The piston travel at TDC is the same as OEM, flush with the deck. I’m thinking of trying breaking the chain and adding a link but will have to find the roller because I don’t thing a half link will clear the case on the crank sprocket. Do you know the number of the roller chain? It will be my luck it’s like the 21 count spline universal yoke and a Polaris only part.

[@abels_04]

Picked up a sportsman 500. Oil level was dead on the mark. Was getting it running and air box filled up with oil. Oil level dropped. Im guessing its pulling oil but not returning to resevior filling crankcase up and blowing out the breather. Any tips on what i need to check for?

[@TitaniummanGarage]

You will get some oil in the air box. But not that much. My guess is it could be the valve seals leaking. Have you checked the valve lash? If the valves are not set correctly that could be an issue too.

[@abels_04]

@@TitaniummanGarage i have not gotten to adjusting valves yet. That was my next step after getting it running till I ran into the oil pouring into the airbox. Ill try that next.

[@daveh2612]

At 37:50 what is the purpose of the gap that’s needed in the throttle lever switch?

[@TitaniummanGarage]

Its a safety kill switch if the throttle cable breaks. There needs to be a gap. If it it closed it thinks the cable is broke ,closing the connection telling it to shut the engine off electronically.

[@rrwoodworksmore9239]

I got a question, I'm a pretty good mechanic, but for the life of me, I can not get my 500 ranger right, what it is that it will not idle on its on till 20 minutes of riding or so , tried 2 new carbs, same thing. It's a 05 polaris 500 ranger, any suggestions?

[@TitaniummanGarage]

Sounds like a issue with the choke. Might need adjustment. Also if it's cold out. It takes a bit for it to warm up before it will idle good.

[@wayneb2869]

Do you have a business doing this work? I have a 2005 400 needing a rebuild.

[@TitaniummanGarage]

Yes. I do. Where are you located?

[@wayneb2869]

Couple hrs south of you.

[@RichardWells-ft6sf]

I would be concerned about the stoke of the connecting rod pumping up the cylinder???

[@TitaniummanGarage]

It won't. I've done it several times. I've had that comment alot. The piston sits dead flat on top dead center with the top of the cylinder. If anything it gives it better compression.