How to Trouble Shoot issues on a Polaris Sportsman 500!

I'll walk you through the steps how to figure out your issue on your polaris sportsman 500

[@hossHoldem]

I've watched so many videos to help with troubleshooting Polaris ATVs. This is by far the best and breaks it down to simple checks so you don't waste time replacing parts that aren't bad. Thanks for posting!

[@michaelchaoticreason5059]

Very nice! I never thought to adjust the valves with the tank still in place! Saves a lot of time not having to take the plastic off and all that. I don’t think I’m quite there yet. This is my first quad and my first breakdown. Thank you for all your help and for all your videos. Truly saving my bacon!

[@michaelnorthan5981]

Great content! Really appreciate the info! I'm working my way through a 1999 Sportsman 500 and seeing similar issues. Next step is to look into the top end and check the valve lash and the cam. I really like the systematic approach to eliminating possible problems. Fuel, spark, compression, TIMING! Great job!

[@jbughuntorjaxonsimpson2185]

I’m having same problem on a 1999 sportsman 500 too, right now I know I have to get a new camshaft but also I can’t seem to find the spark plug boot or spark plug

[@willson8686]

EXPERIENCE , i just can thank you enough, I am learning about this whole new world for me , thanks for posting this

[@osbornebay944]

You are the real mechanic man! l just got a none runner 2002 Sportsman 500, was told there is a big hole and rod went through the bottom, but by pulling the cord over and over, felt engine did not blown. Will follow your 4 steps golden rules to figure out what is wrong with it.

[@TitaniummanGarage]

Right on! Good luck. Hope its an easy fix!

[@offthestreetsandinthecreek7294]

I didn't get a notification? Found it on my feed. Never the less I'm here 💪 great video

[@brandonsmith5743]

New follower just bought my first one. 98 magnum 425. She's is a fixer upper, but I'm liking it. Thanks for the videos still have to do the shifter linkage adjustment

[@rogerracicot8804]

best self repair video i've ever watched...very good ...keep it up...THX. very much..look forward to see more....

[@jackgiljr]

Great troubleshooting vid. This should help a lot of people. Good job!

[@TitaniummanGarage]

Thanks man!

[@boblynn9168]

Good stuff! Thank you for sharing your knowledge!

[@scottschrank4823]

Congrats bud!! Watched your video in florida.. ! Goodjob Tman

[@TitaniummanGarage]

Nice..How's the weather?

[@mechanicforlife9468]

Good video. You can still check compression with the automatic decompression system. It should show between 60 to 90 psi.

[@jaywinters2483]

Fantastic video!

[@user-nf7ui7dz1z]

Titaniumman(s) garage is legit! ..."I knew she was bad when I lost vacuum with my finger on the hole?" I love comedy! I don't even know what you said, but thats what I heard! LOL In all seriousness though, I have a 2006 Polaris Sportsman 500 HO EFI and your vids seem to be all for carb problems. Any chance you will be making videos covering Polaris EFI and their electrical issues as well? Either way, you make excellent content and I (not a mech) have learned a ton! Thank YOU!

[@TitaniummanGarage]

LOL. Glad you enjoyed it.

[@mikegibbons1472]

Glad you explain cause and effect. Stupid little things cause the bigger picture issues. Always shitty when ya get to think it over walking home lol

[@Nakai2024]

awesomeness, thanks !

[@joerutkowsky3261]

Thank you for this video. I have a 2006 sportsman 500ho with 5036 km on it when should I replace the cam? When do they usually end up going? Please let me know what you think. Thank you.

[@fernandogodinho9656]

Amazing

[@brianweber1424]

Good day, I am looking at replacing the piston, cylinder and gaskets on my 2004 Sportsman 500 and see a few kits available on Ebay.....would you recommend any of these for this job ?

[@shirleystassel9457]

enjoy your video, 1997 500 sportsman issue of turning over very hard,.replaced compression release lever seemed to help some times. cold engine turns hard once started it works . should I have replaced cam ? the lever had a groove worn in it. thank you

[@joshjosh6842]

The wizard 👏

[@osbornebay944]

Completed a top end renewal for a 95 Big Bear, free up the carb fuel needle, smoke is gone, was hardly idle, now purrs like kitten.

[@jimhammms]

Mr Titaniumman, are parts from 2002 sportsman 500 and 2004 sportsman 600 interchangeable? Keep up the vids. You’re quite the teacher!!!

[@TitaniummanGarage]

Thanks. The 600's are different. Depends on what part you are talking about.

[@321mattym]

Hey Titanium - Videos have been very helpful to figure out I was having the worn cam issue on my sportsman 500. Question I have for you is after putting in new cam the pull start is extremely hard to pull (tons of compression). I did check and recheck the decompression valve and that is working as it should. Even electric start gets jammed up trying to start. Anything else I can try checking to get rid of some of the compression? I did also check and recheck valve lashes but no luck.

[@TitaniummanGarage]

Let me guess? Aftermarket cam? I had that issue too. Still decompression ball.

[@rob3534]

do you have to replace the rockers when you replace the cam shaft? Is the lash going to be different if you use a aftermarket cam shaft?

[@MOUSEBOWEN]

Awesome video.spark fuel. Compression and Air

[@TitaniummanGarage]

Thanks. Your version is for a 2 stroke though.

[@MOUSEBOWEN]

@@TitaniummanGarage oh so four stroke doesn’t need Air ?

[@TitaniummanGarage]

Yes they do. But then again I suppose that would have to do with timing. If the timing is off the air is pushing out when it should suck in.

[@MOUSEBOWEN]

@@TitaniummanGarage totally agree

[@joshclark7980]

Hello Titanium garage! So my 04 500 ho runs good and fast until i stop. Then it dies. Starts rite back up. Runs good then dies again with throttle. Also 4wd wont work. Not sure if related, probly not? Changed carb and no better Any ideas? Thank you. Love your channel! Lots of good information about shit, thank you.

[@rogerracicot8804]

where's the best place to get a good cam shaft for my 2002 sportsman 500...new or used ??? i no u say ebay but i'm in Ontario Can. what is a fair price for one...??? Thx again i love your videos very helpful....Roger Racicot in Englehart Ontario ...

[@michaelbarnes7086]

Thanks for the video pal. I have a sportsman 500. 2001yr. It has new cam, chain and guides. Battery etc. Was running fine. My nephew was riding it. It just stopped. I sprayed starter fluid in airbox up in carb. No start. In your experience. What could it be. It turns over great. Just no fire. Thanks

[@TitaniummanGarage]

Check to see if you have spark. could be a bad cdi or kill switch.

[@dustinbranham5373]

Good troubleshooting. I have a question about my sportsman 500 it's hard on the Initial start like the engine had a lot of kickback once running and warmed up it has very little power so I took the valve cover off thinking the cam was bad but the lobs seem to have no to very little wear. What would be the next thing to check? Thank you for any feedback..

[@TitaniummanGarage]

Decompression ball on the cam causes that. It sticks open.

[@davebean2886]

Do you ever do any paid virtual consulting on Polaris Sportsman 500's? Obviously, there are limits to what can be done remotely, but perhaps an advisor to help might be a good idea?

[@danielvega8188]

Any chance i can send my polaris 2002 to your shop to get it fixt up??

[@EdwinMcnoFearSon781]

@titaniumman garage Have you ever switched out the carb on a scrambler 500? I put a mikuni tm38mm flat side off of my cr250 on mine, eliminated the fuel pump and rejetted it and it def did give her a good amount more snot,That is until I blew out the cam, replaced it and now can’t get it running right again. Super frustrating I probably tore it apart 20 times now and every time get somewhat different results. I dk if me only putting cam in and not rockers would affect it in that manner but now it’s real hard for the cam to rotate and open exhaust valves which in turn is making it backfire and pop out the carb I believe. Runs decent until oast 1/4 throttle then sputters and backfires and has loss of power simikiar to when I blew the cam the first time. The exhaust lobe does look to have some wear on the one side of the exhaust lobe like it was rubbing something that ground it down a but I don’t see how it can be shot already considering I didn’t even put one hour on it since I got the new cam. Guess I should probably check it with micrometer now that I know the measurements you mentioned in this video. Any input or suggestions would be appreciated man and thanks alot for your videos your def the biggest help when it comes to Polaris quads in my opinion and will continue to point people in your direction that need some help with their quads.

[@TitaniummanGarage]

Thanks Man. The decompression ball is what is rubbing that grove in your cam. I put a slide carb on a scrambler once. Definitely more snot to it. the problem is it runs lean. Probably why you blew the cam out. I was told that it would run lean and put the stock carb back on. Installed a better clutch with a kit and it had the same effect.

[@EdwinMcnoFearSon781]

@@TitaniummanGarage thanks mines honestly running rich, but regardless think I’m going to have to go back to stock carb . Thanks again for the input and for just taking the time to get back to me in general, appreciate it. Have a good one and keep those vids rollin! 👍🏼😎

[@richardsoule278]

Hey when you hooked up your external tank to carb, you were on the gear shifter side of carb. this is correct? and p from fuel pump goes on the other side of carb,, thanks working with nothing here..

[@TitaniummanGarage]

Depends if its a H.O. or non H.O carb. I should have showed it from the other side. It was a Non H.O. carb. So I hooked the fuel line to the left lower fuel inlet.

[@Upliftyourbrothers]

Thanks for the videos- quick question: I’ve got a 1999 sportsman 500. Has always ran great, recently it seems to have a rev limiter, both in drive, and neutral. It feels it’s like quarter throttle- feels limited by electronics. It doesn’t change when I press the ‘override’ button.

[@mikegibbons1472]

Your button on Rev limit er is pouched probably.

[@12reks]

Any update? I seem to have the same issue rev limiter half throttle but in neutral when i push te override Its seem to be ok …

[@kippiemoore7439]

How do you adjust the choke?

[@TBone1234561]

I need some help on one Ive got an older 500 sportsman has fuel, fire, compression. It's had a complete new top end installed crankshaft woodruff key is in perfect condition did have an oil leak around the stator housing taken care of now possibly ignition timing?

[@TitaniummanGarage]

What is the issue?

[@TBone1234561]

@@TitaniummanGarage no start sounds like it almost wants to bust off but then again my Bendix disengages right at that point but have a new OEM one on the way just to test but got it on a trade I've ran my way through them before and always got em going but this one appears to have a whole new top end compression blows my finger off auto decomp is working on the cam loves are good intake and exhaust clearances are set at .06 in timing appears to be good but not sure on the ignition timing I have a manual on the magnum 425 same basics?

[@ericksarellano127]

Tengo una sportsman 500 1998 y batallo mucho para encenderla. ¿Que podra ser?

[@christophernichols8247]

Really hoping I can get this fixed but I recently got my polaris sportsman 500 back and the battery was dead. I tried to charge it but I found out that my battery had a bad cell in it so I hooked up another one and It tried to start by itself. It always drained the 2 batterys I tried to put in it? I got a new motor,new solenoid and everything. Im thinking it could be a starter? Id appreicate the help.

[@TitaniummanGarage]

The rectifier is what charges the battery along with the stator. Maybe replace the rectifier and clean all your ground wires. Those will cause the battery to fail as well.

[@ronhanish]

while u got spark plug out spray either in hole that will tell you real quick if its a fuel issue.

[@paulodias6148]

Hi, I have a 2000 Polaris Sportsman 500 4x4. When cold starting electrically it will crank crank crank pull. Start it two or three times. Fires up then eletric starts electric.

[@TitaniummanGarage]

They are hard to start when cold. Does it fire up at all?

[@damiandelapp5490]

I picked a 97 up with a blown head gasket from a fan switch failure with 2200 miles on it, cams were fine, re-ringed it, surfaced head, jiffy kited the carb, full service, what cause’s a cam failure like that?

[@TitaniummanGarage]

Coolant in the oil.

[@user-tv2df2mq5e]

If you plug the black wire back in and put the boot and plug back in and now you have no spark again,what does that mean? I unplugged theblack wire and took the spark plug boot out along with the plug and since I unplugged the black wire. I have lots of spark but as soon as I plug the black wire back into the cdi box and put the plug back in now I have no spark so what does that mean?

[@Esser44]

Test the ignition switch, engine stop switch, and speed limiter circuit for shorts to ground.

[@tomchrest1628]

I have a 2006 sportsman efi 500 HO that won’t start. It has spark, compression, fuel. When attempting to start it sounds like it’s back firing a little. I checked the valve lash and set to .006 but no luck. Any ideas? I thought about changing out the cam, but don’t want to just throw money at it, if not needed. Help?

[@TitaniummanGarage]

You dont need to replace the cam. I have a video how to remove it. You can inspect it. See if it's still good. You could just take the rockers off and see if the exhaust lobe is warn out by rotating the engine.

[@micahl9075]

Hey I have a 00 sportsman 500 and when it’s running it has a rattling sound on the right ride of the motor what do you think that could be

[@TitaniummanGarage]

Could be the starter bendix or something in starter recoil. Could mean your valves need adjustment. Hard to say without looking at it. Or chain slop.

[@andrewfitzgerald9417]

A little off topic here... I have a 98 sportsman 500 and the transmission is tired. I have a complete 02 sportsman 400 parts bike with a good working trans with axles and everything else. The only difference I can see is that the 400 has connectors on the top that the 500 does not have. Any thoughts on switching them out?

[@TitaniummanGarage]

Do you mean the plugs by the tranny. Thats for the 4x4 for the shifter and shift indicator. You can by pass those.

[@andrewfitzgerald9417]

Ok thanks. As long as it physically fits I hope I can figure out the rest.

[@HifumiShimizu]

I have all those issues now she does not start anymore I change the solenoid the battery and the carburetor I checked out the starter she's good not getting the fire to turn over the engine

[@deonnnnnnnnnn]

I got a 2000 - 2001 polaris sportsman 500 ho, it used to start with e start, put a new battery in it and then wouldn't start with e start but would with the pull cord, now it has no spark, I had people look at the stator and said it was good, put a new pickup coil on it and still nothing any tips what it coil be?

[@TitaniummanGarage]

Run/stop/Kill switch might have corrosion on it. Or a bad ground wire somewhere. Try pulling the black wire on cdi. see if you get spark...or it fires then.

[@carlosdominguez3053]

Very informative video pal. Can you help me out with my 2000 polaris 500. It runs a distance and it shuts off completely. I wait for a couple minutes and when I turn it on it runs and off it goes again.. Any tips or advice? Best wishes and hope to hear from you.

[@TitaniummanGarage]

I would start with the cdi. Some cdi's work at first but at higher rpms it shuts down. Is it overheating at all? That would cause that issue as well.

[@carlosdominguez3053]

@@TitaniummanGarage yes my Polaris 500 does overheat a lot. Is it normal? Does anyone know the normal heat temperature for the polaris 500 magnum 2000?

[@TitaniummanGarage]

That is your issue. It is not normal. I use a temp gun on them. it should be below 190 I believe. Mine normally runs about 130 at the radiator and 97 on the hoses. Check to make sure your fan is working too. I have a video how to check the fan.

[@carlosdominguez3053]

@@TitaniummanGarage my fan is working well. I have disassembled the water pump for debris but it was clean.. I will be adding the thermostat because it is working well. I ordered a new cdi from Amazon but I was sent the wrong cdi. I have have messaged Amazon concerning that issue. In their Amazon spec and images they had the exact cdi for the one I was ordering but got a different one... Do you believe that the Amazon cdi would work well?

[@devoncauley9297]

Hey Titaniumman we ( my father and me ) found out what the problem was the coil not grounding

[@TitaniummanGarage]

Nice catch!

[@elainecarter22]

What do you do when there is no spark? 99 sportsman 500. Battery good, solenoid good, changed starter.

[@TitaniummanGarage]

Try and unplug the black wire on the cdi box. It should give you spark. If so, it's a bad cdi or issues with your kill switch on the handle bar.

[@michaelchaoticreason5059]

Do you put Moly on your new cam when you install them? Or do you just pour some oil over everything while you're putting it back together?

[@TitaniummanGarage]

I used to build engines for a living. We put whites lithium grease on the all camshafts So I go that route.

[@michaelchaoticreason5059]

@@TitaniummanGarage Thanks a lot good sir. ;)

[@michaelchaoticreason5059]

@@TitaniummanGarage Fair enough. Thanks a bunch. I actually have 1 more question. When you replace the cam, do you replace just the exhaust rocker, or all 3 rockers?

[@TitaniummanGarage]

All 3

[@christianangeles3259]

Hey I have a 2000 polaris sportsman 335 that's running ok idles little low but smokes from the exhaust what would be the reason it's smoking white smoke

[@TitaniummanGarage]

Usually, white smoke is a head gasket. I would check your sparkplug to see if there is any coolant on the plug

[@christianangeles3259]

@@TitaniummanGarage sounds good I'll check that thanks for the info I also commented on one of ur vids about a 2006 sportsman 450 carb adjustment if u can help a brother out it runs then just dies starts back up after a minute or two runs and dies again has new carb Chinese according to previous owner it does look like he replaced it but maybe messed up the adjustment

[@TitaniummanGarage]

@@christianangeles3259 I would try a differnt carb. Some of those china carbs are garbage. Some arn't. I just cleaned a china carb putit on a 700 and it ran like crap. i swapped it out for a old Mikuni I had and it ran good.

[@austinjackson8248]

I have a 99 sportsman 500 it backfires through the exhaust most of the time one time I choked it and it blew the carb off. Revs fine backfire when idling back down and slowing down. What would cause this?

[@TitaniummanGarage]

Sounds like your loading up with fuel. You have to be careful now that it blew the carb off. It could have did damage to the diaphragm on the carb. Check the spark plug. If its black your getting too much fuel. I would also check the timing.

[@austinjackson8248]

@@TitaniummanGarage thank you. How to I fx that?

[@TitaniummanGarage]

@@austinjackson8248 check the carb. make sure the slide goes up and down when its running and giving it throttle. adjust the air/fuel screw at the bottom of the carb.

[@justingrady1964]

So if the cam is bad the intake valves will be tight? Reason I ask is I have a 500 that will not accelerate and the intake valves are tight.

[@TitaniummanGarage]

When you say tight, do you mean the valve lash? Every so often you need to reset the valve lash because of wear. The chain will stretch as well.

[@justingrady1964]

@@TitaniummanGarage Valve lash is what I mean. This wheeler idles perfectly but bogs when you throttle up. The intake valves were tight so I adjusted to .006. The cam is within spec 1.28 and has a good lobe not like the ones I have seen on your channel. Cleaned carb, checked diaphragm, jets, float height and all good. I have a gas caddy so I piggybacked it to the carb to eliminate the fuel pump being a issue. I'm at my wits end, any pointers would be helpful. Thanks.

[@TitaniummanGarage]

The choke cable could be stretched and need adjustment. Also it seems no matter how many times you clean the carb. Unless you put it in a sonic cleaner, if wont be right. I would try a different carb.

[@justingrady1964]

@@TitaniummanGarage I adjusted on the choke when I cleaned. How are those knockoff carbs. Also, could it be CDI or timing? When the mark on th flywheel is lined up the two dots are at the top of the cam wheel. If it was off a tooth would it make that much difference?

[@TitaniummanGarage]

@@justingrady1964 The knock of carbs are OK..it depends. Sometimes you get good ones, sometimes there not good at all. I have a customer that has had one on his magnum I built. It's been 3 years now. Still running good. I bought one the other day. I couldn't get it to run right so I got a clean oem carb and it worked good. If a tooth is off it will run like crap. Even if the chain is stretched it will open the intake before it should. Actually that was my next suggestion. To check the timing

[@mr.octopus6972]

My 98 was running just fine. I parked it for 2 days in front of the house then it won't start anymore. It seems like it wants to go on, I get 1 to 3 burps out of the muffler the first time I hit the starter but nothing more as long as a press the switch. I wait a little bit, hit the switch again and it does the same. "Burp burp dead" So far the only thing I checked is the fire which is fine. What would be the next steps to troubleshot this ? Carb ? Gaz ? Timing ? HELP ! 😅😅

[@TitaniummanGarage]

I would start with the carb and while the fuel line is disconnected check to see if fuel is flowing out of the line. The lines could be soft and collapse or dirt in the tank or a bad fuel pump. The jet on the carb could be plugged as well.

[@TitaniummanGarage]

Also being a 98 it could be a bad camshaft. Maybe check that first. Pull the rocker cover off and look for worn cam lobes. 98 and 99 had bad cams.

[@mr.octopus6972]

@@TitaniummanGarage Thank you. Indeed it was the carb. I had a brand new one in the garage, replaced it and it starts A1. The old one hasn't been cleaned in two years it was wery dirthy.

[@rickjosephsen8923]

At my wits end. I have a 2006 Polaris sportsman EFI 500. All electric good fuel pump new injector new. The bikes only got 200 hrs never touched it never ran hard all of a sudden won't start. If I spray starter fluid into carb it will run. Help

[@TitaniummanGarage]

Did you purge the air out of the fuel lines after fuel pump was installed? also did you replace the fuel filter? That might be plugged.

[@rickjosephsen8923]

@@TitaniummanGarage yes and yes. The fuel is pumping great. And the injection system is pumping. Good spark the thing that gets me is I can spray starter fluid into the carb and it runs fine. That said I'm confused on my next move. P.s thank you so much for replying.

[@TitaniummanGarage]

@@rickjosephsen8923 did you pull the injector to see how much was coming out? I had the same issue. I pulled the injector. Fuel was spaying out. At the time I didnt know how much had to spray out. It still wouldn't stay running. So I pulled the fuel pump again and found that the round fuel return thing popped off. I had to use a hose clamp to get it to keep it from popping off again as the clip holding it was bad. I assembled it and fuel came gushing out of the injector fast. Before it was a light spray. Problem solved. You might want to check that pump again.

[@rickjosephsen8923]

@@TitaniummanGarage check. The injector is putting out move fuel then I expected. I removed the line to it and the pump poured out a ton of gas. Back to me spraying into the carb. I ran out of ether and even used carb cleaner and it ran on that. Could the timing be off, b t w I can't believe that the dealer turned me down for any repairs because it's a 2006. Man what's going to happen when Drs say dude your to old to operate on. Tnx, Baffled

[@rickjosephsen8923]

Hi guys. I wanted to say thank you for your input. I think I should say again WHY can I keep the ATV running when I spray a fine spurt of starter fluid or carb cleaner. I feel I'm so close just missing a fine line to fixing this. Thank you again. Confused 😕

[@22mudman]

98 sportsmen 500 i was letting warm up it just died i changed cdi new battery new starter cranks but no fire

[@TitaniummanGarage]

did you check the coil?

[@davebean2886]

4 things to start? Fuel, spark, compression, timing. What about air?

[@TitaniummanGarage]

The timing would include air. But yes your correct.

[@tomgilligan4705]

ecessive heat on exhaust side of my machine

[@jandeband]

Shooda showed cam replacement

[@TitaniummanGarage]

I have a video on that already. Check out my videos

[@twandiastennis6265]

Where are you location.

[@TitaniummanGarage]

wisconsin

[@ed631941]

I think that you are mistaken about the compresion release ball. If the ball is STUCK in the OUT position,it will RELEASE compresion and the engine will turn over easily with the pull start rope. When the engine starts,centrifical force rotates the compresion release shaft and the cam folower SHOULD push the ball back down in its hole. Edwin Dirnbeck