Polaris Outlaw 500 out of time.

Working on a 2006 Polaris Outlaw that went out of time.

[@kylemccracken4724]

Thank you

[@mannymarquez6356]

Great video I have a 2005 Polaris predator that has a crank no start and it’s out of time I’m going to Check the timing and this video is exactly what I needed as a guide

[@mg016]

Thanks!! I hope you get your Pred working.

[@juaritoz31]

Sorry to late lol. But did it work?

[@juaritoz31]

Do you have Instagram?

[@davidmccurdy5199]

Great video, very helpful. Thank you

[@mg016]

Thanks!

[@pimentel85jp]

Very good video and well explained. Thank you

[@mg016]

Thanks!

[@williambasco2404]

Great video most people don’t no that

[@eltorreja86]

The magneto removal tool is 33 mm

[@nochan99]

If the key was sheared like that I would suspect the tapered bearing surfaces not to match 100%. It is not the key but the tapered surface that should ensure a solid fit. A fix for that is to 1. remove the key 2. put some coarse valve grinding compound on the bearing surfaces 3. grind the bearing surfaces by moving the flywheel back and forth 4. clean of all residue with a clean cloth and acetone 5. repeat steps 2 -> 4 with gradually finer compound. Now the surfaces have been ground to fit perfectly and you can put the key back in and rest assured they mate perfectly and with a properly tightened bolt, the surfaces should not slide.

[@danielfl.9347]

Great video. These Fuji-Subaru engines are pretty good, but needs maintainance

[@k-hacks1360]

Made a hammer just like yours lol.. regular hammer ruined my first woodruf key

[@wrenchboostboi8994]

Bro, my 2017 polaris 450ho sheared the woodruff key and the advanced enough that the piston hit the valves and grenaded the engine. I gotta pull the whole thing apart and start my rebuild… hopefully just top end damage but we’ll see. Bike has less than 500hrs on it

[@bobbymedders4427]

I've got a 2006 Outlaw. Do you have any spare parts for that model you'd like to sell? Thanks for the video! Mine had the same problem.

[@mg016]

Sorry I don't have no spare parts.

[@chrislangley363]

Any idea of what could be wrong with mine (just did a fresh top end rebuild motor TDC cams haven’t spun key way is good 😭I was hoping you would solve my problem but I appreciate you video like way simper str8 to it

[@eladionunez2032]

Nice

[@augustin2105]

Right on✊️🤙

[@michaelmullins6479]

Bro I need your help bad I got the same problem but I can’t figure it out and it just spins

[@k-hacks1360]

I put everything back together and eventually (after several rides) when I start it up, sounds like something gets stuck or metallic clanking and breaks off the woodruf key and then the flywheel bolt unscrews. You think it has to do with the starter clutch being bad or is it just me not tightening the flywheel down hard enough ? First time I did it with an impact wrench, second with a breaker bar.. still broke and everything came loose both times.

[@wrenchboostboi8994]

For one you gotta torque it to spec. For 2 after shearing a key you should get some lapping compound and lightly reface the mating surface between the flywheel and shaft. Dab a bit on there and hand spin the flywheel about 20 times around then clean off all that compound really good. Also sometimes depending on the machine you can sometimes get away with buying a whole kit of keys and using a slightly oversized key, then lightly sanding it down to fit. This guys job Will likely only work for a little while until it shears another key.

[@k-hacks1360]

@@wrenchboostboi8994 happened over a year ago, it was actually just the surface. Cleaned off before putting everything together, torqued to spec and It worked

[@k-hacks1360]

Would the broken woodruf key make it get out of time?

[@mg016]

Yes it will.

[@frankvaldez9700]

So once you replaced the woodruff key how did you get the timing marks on the cam gears and the timing marks on the flywheel to match up again?

[@mg016]

I used the gold marks on the timing chain to match up with the dot marks on the cam gears and the lower crank timing gear.

[@codylauck4930]

so you would get it at top dead center. then you would loosen the chain using the cam tensioner remove the clutch cover and line the gold marks up one on the dot at the lower cam gear at the clutch and have your cam dots at 9 and 12 o clock on both make sure your cam lobe on the exhaust is facing towards the exhaust and the intake to the intake

[@codylauck4930]

you don’t need the gold marks but it’s easier i prefer not to bc i like my exhaust a little more open

[@jovanemontes80]

Hey there u would happen to have a new head for a Predator 500? Mine cracked.

[@mg016]

Yes I do, well not new but used in good condition.

[@codyweien4513]

How much you want for it?

[@jovanemontes80]

How much for it?

[@ManwantSinghMultani]

How do you fix a leak that you have where the carburetor gas screw is ? If you have it tight all the way and it still leaks ?

[@mg016]

Do you mean where the screw is under the bowl. Or are you talking about the fuel mixer screw.

[@ManwantSinghMultani]

@@mg016 you know the screw, and where it has a whole underneath where does the line go for the extra leakage?

[@davelindsley9838]

Great video buddy I have one question for you I have a Polaris predator 500 it's at top dead center the intake cam I cannot get a filler gauge in there I know it's supposed to be at .006 intake and the exhaust.010 so do you think they make a shin small enough or should I just put new valves in it I would appreciate the help thanks

[@mg016]

Yes they make thin shims. I worked on a Pred once and the intake was very tight like .002in I ended up putting a 1.25mm shim. The other intake was a 1.50mm

[@davelindsley9838]

I can't fit any filler gauge at all in there not even.002

[@mg016]

@@davelindsley9838 I couldn't either, the smallest filler gauge I had was the .002 Make sure to buy the 2003-2007 HOT CAMS 9.48mm Valve Shim Kit for the Polaris Predator 500

[@davelindsley9838]

I was watching another video and the guy was having the same problem when he took the head apart the valves are so worn they were sharp like a knife on the side I don't want it to ruin the head so I think I'm going to replace the valves I haven't torn apart the motor yet do you think that's a better idea and just shimming it then running into a bunch of problems later my bike is really clean like new

[@mg016]

@@davelindsley9838 It could be the valve face or the valve seat on the head that's worn. Either way make sure you lap the valve to the head with lapping compound.

[@eduardoandrade662]

Got a question I got a 05 Polaris predator 500 with the plastics kinda broken, whats a good price to sell?? It’s got a fully rebuilt top end

[@mg016]

Do you have any mods on it? If so it helps to bring up price. Base what you said I would say $3,000-$2,500

[@eduardoandrade662]

@@mg016 thanks my guy I appreciate you for actually responding, it’s cuz I kinda wanna get into dirt bikes now lmao

[@juaritoz31]

Where did you get the pulley puller or what is it called??

[@mg016]

eBay. Flywheel puller.

[@juaritoz31]

@@mg016 thank you

[@juaritoz31]

Hey did you ever get the size of the pulley puller/ flywheel?

[@codyweien4513]

It's pronounced wooDRIFF key.

[@edisonsela937]

Good you find the problem, why it jump the timing I did understood what you did to fix it and to prevent not to hapend again, maybe the chain is stretch needs new one 99

[@mg016]

I compared the exhaust & intake cams to a set I had available and and they looked exactly the same. So retimed it and reassembled everything back. I test rode quad and had no issues. Honesty I don't know what happen. But I did mark the cam gears so if next time it happens I will be able to see if gears moved(spun).

[@jct3996]

Where can I order a woodruff key for a Polaris predator 500

[@mg016]

Ebay for about $10 for one or Harbor Freight for an assortment pack for $10. And in that assortment you get 10 pieces for the size you need for the Predator.

[@jct3996]

Thanks brother ! Awesome video a lot of information hopefully you keep uploading more 👍

[@rodneysanders5893]

What kind of pulley is that

[@mg016]

Tusk Flywheel Puller Remover 33mm POLARIS PREDATOR 500 2003-2007 magneto rotor

[@hector-rt2lc]

I have a question why does my polaris outlaw 500 not start with out a push it wouldn't start

[@mg016]

It could be many things. What happens when you use the push button?

[@hector-rt2lc]

@@mg016 the spark works and all but and it makes the sound like if your going to turn it on but I dosent you know what I mean ?

[@hector-rt2lc]

@@mg016 so what do you thing it could be

[@mg016]

@@hector-rt2lc how is your battery? Is it fully charged, have you tried using jumping cables. When ever my battery tends to get low after trying to start the quad I'll jump start it with one of my vehicles. If it doesn't work then it might be the Oneway Clutch has failed.

[@hector-rt2lc]

@@mg016 yes that's what is happening i think but when we pull it with another attitude turns on

[@sarathsruthy8105]

Plz help