1996 Polaris Sportsman 500 runs bad. Fixed - Thanks.wmv

[goofienewfie45]

this bike sounds like the same issues as mine check the carb and clean and check your cable inside mine was bogging out like yours after that it was fine and still got it

[chevyman1500ful]

it sound to me like the throttle sensor or one of the pistons sounds like its bad. Where did you get it and how did you drive it before that sound came.

[integramyke]

your problem could b oil passing through the valves , restricting air flow.or timing

[reidslimshaddy32]

its the cam ive had the same problem my friend also had the same problem and he put a 500 scrambler cam in it and it goes like 15 miles faster

[39herring]

Honda and polaris are the best

[chevyman1500ful]

@39herring you are totaly righ on that one.

[roryzack]

its the cam

[MrGearHead]

hvfd122 You are dead on. THANKS! The exhaust lobe is almost gone. I noticed the lack of exhaust vavle travel when I had it apart but thought (no way is the lobe wore down that quickly - 800 miles) That begs another question. Is this problem due to lack of maintenance by the previous owner or a bad cam/rocker design? Now that I am researching it, It seams like a lot of people are having this problem. Change oil and filter on a reg. basis and the motor lasts forever? Chime in anyone?

[MrGearHead]

@MrGearHead The new cam had 2 (and larger in diameter) oil veins on the exhaust lobe. Polaris still says it's not their fault. It's not there fault when I buy a Honda next time either!

[hvfd122]

I Hate to say it, but i fought this on my 97 sportsman 500. I did all that you have done and then i was so fed up i took it to a shop. It was the exhaust lobe on the cam. Also had to replace the rocker arm. It was an easy fix I could have done myself, but i went ahead and let a Pro do it. It cost me 450$ in parts plus 250 in labor. But now its a Mean Machine! I hope This Helps, Also you can go to Mud in my blood.com and they have a help forum for Polaris and all other's.

[MrGearHead]

The machine has 800 miles on it. It gradually got this way. What I did to try an fix it: Drain the gas and replace with new + Change and gap new plug + Clean carb X2 + Set choke and throttle cables + Disconnect muffler + Clean foam air cleaner (that covers the pleated one) + Checked flywheel key-good + Checked valve clearance-good + Compression check = 125 Psi. at 5 compression strokes. NOTE: There was 3 Oz. of oil in the air box when I started this repair project. Any ideas?

[12345678969169]

@MrGearHead wouldnt hurt to clean out the carburator because i have a honda rancher 350 es 4x4 and that carb needs to be ripped apart and cleaned and honda dont break... usually