Polaris 500 Head Gasket Replacement and Torque Sequence

[@toms751]

Thanks, Tmam. What you did is beyond my ability for now. I have a '98 500 just bought, and plan to begin w/ simple preventative maintenance, but, it's got some repairs that I will begin after that. 1st will be adjusting or r/r choke, and/or carb rebuild. At 22 years use, its going to need more. Hopefully you'll be able to share more, for what is one of the most numerous ATV quads in the world.

[@TitaniummanGarage]

Tom S. I'm happy you enjoyed the videos. Once you get into working on it, Its really not that bad. I like sharing my knowledge with people and glad it helps them out. I have a lot of videos on Polaris. If you have anything specific in mind..let me know.

[@parrishmooneyham6095]

on a written version, which what I needed for my 1997 Polaris Xplorer 500, here is that: "Torque all bolts evenly in a crisscross pattern": *Torque bolts to 22 ft. lbs. (3.04 kg-m) *Torque bolts to 51 ft. lbs (7.04 kg-m) *Loosen bolts evenly 180 degrees (1/2 turn) *Loosen bolts again another 180 degrees (1/2 turn) *Torque bolts to 11 ft lbs. (1.52 kg-m) *From this point, tighten evenly 90 degrees (1/4 turn) *Finally, tighten another 90 degrees (1/4 turn) *Install two 6mm bolts and torque to 6 ft. lbs. (.828 kg-m) the Pattern per my service manual is this.. please not that 5 & 6 are 6mm bolts, I couldn't post picture but that is what it shows... 3 2 5 6 1 4

[@kevinlee9751]

Very well done video, not Fluffy with a whole lot needless talk. I'm going to subscribe for Two reasons, one I already mentioned, and the second is I am going to be doing one of these in a few days. I just thought of another reason, and that is more and more people keep coming to me for help. We don't have any actual repair shops within 30+ miles So I kinda help fill in. I get paid in some unusual ways on occasion. When it comes to the Kids around here I get this in trade mostly. The other day I got a Singer Sewing Machine with Cabinet and all (1960s Model) in exchange for making a Header for one Kid. It needs a Timing Belt but it is a pretty good Machine. Who knows I might have to check out some other things you have done. Anyway I really liked the video, Thanks Again!!

[@TitaniummanGarage]

Thanks. I try to give as much detail as I can. I have some videos where I experimented with different carbs, turned a 425 engine into a 500. You'll have to check it out. Keep up the good work. I have people I'm helping too. I usually get parts or other things in exchange for the work I do.

[@justinpaone2227]

The manual actually says to back it off 180° after you do the 51-ft pounds twice , so 360 or a full turn. and then tighten to 11 ft pounds which makes sense because of you back it off 180 at least on mine they were already over 11 ft pounds tight still. My only concern is I backed them off 180 the second time and two out of the four broke completely loose. So I cracked them all loose and then tightened to 11 ft pounds and then finish the procedure crossing my fingers I'll be all right.

[@MrXtronnick]

same here I hope yours still working

[@justinpaone2227]

@@MrXtronnick so far so good

[@joecento4585]

you suppose to loosen bolts 180 degrees 2 times then 11ft lbs then tighten 90 degrees 2 times i think in the video you say loosen 180 1 time

[@travisrosenberg22]

How did you know the head gasket was bad and coolant was on your piston?

[@rockalliance8815]

I’m having issues with compression, it reads 30 lbs and won’t start. I was told it could be the rings, do I have to go through it the same way you did here to check on them? Or is there an easier method. I’ve been fighting my machine for two years lol need help Thanks 😎

[@daddyjmr2008]

Great video. One question. If you do not lose the timing chain, can you just reconnect it once you get the head back on without checking the timing? Also, are there any water jackets in the bottom jug gasket?

[@chrispiatt3801965]

When i tighten rocker arm blocks the cam gets stiff to turn? I have all lash adjustments backed off and not touching.

[@TitaniummanGarage]

Is it a aftermarket? I've had the same issues. But if the rockers are loose what is stopping it from turning? I've seen worn heads where the cam sits..the holes are scored bad causing the cam not to turn properly. Or the weight for the decompression ball not in the correct spot.

[@timrussell1559]

I have a scrambler 500 with the exact same head gasket issue. Debating whether or not it's even worth the insane amount of work it takes to tear down and replace that gasket. This thing has been nothing but trouble and one continuous problem after another!

[@TitaniummanGarage]

If you were in Wisconsin I'd buy it from you once the plastics are off it not that bad to do. Leave the engine in.

[@TitaniummanGarage]

You dont have to pull the cam our either. Just the chain.

[@timrussell1559]

@@TitaniummanGarage If i lived in wisconsin i'd gladly sell it to you. Have literally spent more money repairing this piece of crap than i paid for it, and its been maintained and never abused. Appreciate your time and info

[@tomchrest1628]

@@TitaniummanGarage where in Wisconsin?

[@samcicinelli3544]

I have low compression on a '99 Sportsman 500. Tore it apart and am replacing rings. Rings appear very thin. Visual and leak check on head appears fine. New rings arrived (Polaris PN 3087224) One ring is thick and black (no marks), the other is copper with silver outer lining with a "N" marking. Which is the top ring? Which is the second ring? What is the placement of all the rings? There are WAY TOO MANY opinions on this from what I'm reading.

[@mitchrabe2155]

I got this complete and realized I only backed off 180 degrees once. Will it be bad for me to loosen and start all over, or will it ruin this gasket doing this process twice?

[@TitaniummanGarage]

I've done it before. As long as the head isn't warped you should be OK.

[@joshuatreadwell5548]

Why would I have antifreeze shooting out the top of my reservoir cap when it gets hot?

[@miguelcruzes-castro7021]

I have the same problem right now

[@chrispiatt3801965]

Can you replace the rings, jug, and piston while it's in the frame too?

[@TitaniummanGarage]

Yes, I have done that quite a few times..

[@Okielife]

Did you reuse the head bolts? Fixing to do the same on my 500. Debating on whether to get new head bolts also. Thanks for the video, very helpful

[@TitaniummanGarage]

I did reuse them. But it would be better to replace them if you could.

[@gregoryjones-hs6on]

I would replace my head bolt's.

[@atonyrodify]

I Have a question the Torque sequence is 21 lbs then 52 lbs thats 73 lbs then you loosen the head bolts half turn then you tighten the bolts to 11 lbs then a quarter tern numerous quarter turns does that not damage the head gasket? 73 plus lbs crushes the head gasket Thanks for the video I watch everything you put one out good stuff thanks for your time and effort

[@TitaniummanGarage]

I had thought that too. But what your doing is cutting into the jug with the threads. The bolts also stretch. At the engine plant I worked at we tightened them then loosened them then torqued them down again at 80lbs.

[@atonyrodify]

@@TitaniummanGarage Thanks for the Reply Back!!!

[@justinpaone2227]

@@TitaniummanGarage why are threads being cut being they already exist? Also did you use new headbolts. Because i thought head bolts that stretch "torgue to yield" could only be used once. Mine was running like crap with a new and old carb so i got a new fuel pump on the way. But i did look at the cam and its within spec but figured while im in it a little might as well do the headgasket. Hope the niche brand i bought isnt garbage. Thanks for the videos.

[@TitaniummanGarage]

@@justinpaone2227 yeah..that's the name brand that leaked on me. Hope you have better luck. Ideally you should replace the bolts. I reuse mine as long as they are not twisted or bent. Cutting oil is what Polaris recommends

[@lewingjr]

the torques do not add up. Once you are at 22 then going to 52 is only moving up 30 foot pounds

[@dnprgp0]

I just replaced the cam on my 96 sportsman 500. Got everything all back together and running good but now I noticed I'm losing coolant and it's not leaking on the ground. Checked my oil and reservoir is about an inch fuller. Probably because coolant getting into oil? Is your guess head gasket?

[@TitaniummanGarage]

Yes. Did you replace the gasket or just do the cam?

[@dnprgp0]

@@TitaniummanGarage just the cam

[@TitaniummanGarage]

It could also be the water pump. But it would be dripping out of the weep hole. Drain your oil and see how much coolent is in the case.

[@davidegan3934]

great video very helpful just one question you say step 7 ? i count 6 or did i miss something....i am not in any way nit picking just want to be sure before i start thank you !!

[@TitaniummanGarage]

Ha Ha. I was wondering when someone would bust me on that. I did skip a step. The next step was to loosen another half turn, but the bolts were loose enough I didn't have to do it. Nice catch.

[@davidegan3934]

@@TitaniummanGarage oh no worries thank you so much helped me out aallot im doing a headgasket on my daughter scrambler 500 any other advise?

[@TitaniummanGarage]

@@davidegan3934 Make sure the gasket is a good thick one like polaris. Beware of the Chinese knockoff gaskets. They dont hold. Too thin. Make sure the head is perfectly flat so it seals.

[@jhonnygonzalez7799]

You don't have a video on how to put the chain tensioner

[@TitaniummanGarage]

That's a great idea. I'll have to make one.

[@dvcm27]

If im at top dead center. Does it matter if the chain skips a tooth on the crank when re indtalling the cam as long as the 2 dots are facing north? Or is it better to remove the flyeheel and stator to make sure?

[@TitaniummanGarage]

Skipping a tooth is not good. I would pull the flywheel and make sure. Other you might have problems.

[@dvcm27]

@@TitaniummanGarageif the crank sprocket and the cam sprocket are properly time before taking the head and Cam sprocket/ chain off to replace the gasket. The when reinstalling the cam sprocket and the chain, as long as the crank sprocket hasn't moved, it seems to me it should be good without removing the flywheel. The main thing is to make sure the 2 dots on the cam sprocket is reinstalled facing north or the exact orientation that it was before disassembly.

[@TitaniummanGarage]

@@dvcm27 You are correct. If nothing has moved you are good to go.

[@richardli8634]

I’m so considering driving this thing down to you to fix, or a dealership. I rebuilt the top end with a Chinese cylinder head and piston kit. New carb, was running great! Let it idle for a a long time and putted around the yard in low. 2 days later I decide to get into it in high gear, it starts picking up speed and something goes bang and it dies. Found the plug diode bent on itself so in theory it hit the cylinder, but why it did after 2 days of running fine? Any ideas? How much you charge for a rebuild lol, if you are cheaper than the dealership I’ll consider it!

[@TitaniummanGarage]

I dont have faith in any of the Chinese parts. Who knows how it was machined or the tolerances on it.I would have the oem machined. I didnt know they made heads. I just saw cylinder jugs.

[@richardli8634]

@@TitaniummanGarage my correction, yes the Cylinder not the head. So strange though it was fine until I got into it in high gear. I ordered a boroscope to see if I popped a hole in the piston. Should be here tomorrow. You dont by chance have a whole motor for sale do you?

[@richardli8634]

@@TitaniummanGarage figured it out, the piston cracked and threw a chunk into the combustion chamber thus mashing the plug. so I will be taking it back apart again. just wondering now if I have to take the crank case apart to remove all the metal chunks now.

[@TitaniummanGarage]

@@richardli8634 I had to do that. First I grabbed a thin plastic hose and taped it to a shop vac to suck out the metal. I found the counterbalancer was in the way and couldn't get a big chunk out. So to be safe I would suggest splitting the cases.

[@richardli8634]

@@TitaniummanGarage yeah, I figure it is better to not cut corners on the process. I dont want to damage the bottom end. Top end isn't too bad, new case may as well just find a whole new motor.

[@trentelliott1473]

Do you have a video on piston replacement and cylinder honing?

[@TitaniummanGarage]

On a 400 I do. Same principle apply.

[@trentelliott1473]

@@TitaniummanGarage what is the title of the video so I can search for it.

[@TitaniummanGarage]

@@trentelliott1473 kzbin.info/www/bejne/pHLMmmiQbK-rrLs

[@trentelliott1473]

@@TitaniummanGarage thanks very helpful. What brand cutting spray are you using?

[@TitaniummanGarage]

@@trentelliott1473 you can use 3 in 1 oil or WD 40. They do sell a cutting oil but I just use what I have and it works.

[@christopherrowe5639]

If the cam shaft is good do you have to remove it?

[@TitaniummanGarage]

No, you can leave it on.

[@SamJohnson-iq7gg]

Did you have to mess with the timing after you got the new head gasket on ?

[@TitaniummanGarage]

I did have to make sure the timing marks on the gear lined up correctly and check the gap between rockers.

[@JOzArT-cb9ip]

Where did you order the cylinder head from?

[@mitchrabe2155]

I used NFlow. Great price and great customer service.

[@frankverton9891]

Price of the head gasket for 500 high out put

[@TitaniummanGarage]

47 bucks

[@BUBBAZXR]

What are the torque specs for the jug bolts?

[@TitaniummanGarage]

I'll have to look it up. You could always Google it too. I use that alot on torque specs.

[@gregoryjones-hs6on]

​@@TitaniummanGarage I couldn't find the torque specs on a 99 ranger 6x6

[@TitaniummanGarage]

@@gregoryjones-hs6on If its a 500 its 45 to 49 ft lbs