 Let me show you what this bad boy can do. Hey guys, welcome back to the Titanium Man Garage and today I'm doing something different. I'm doing a Polaris Sportsman 700 and I already got things started to take apart and this video isn't only for you, it's for me as well just so I remember how to put everything back together. I did one 700, replaced the motor in it, it's been like three years, yeah I'm gonna film this so I don't forget anything but I got the plastics off, took the tank off, air box and carb, I put the carb in a plastic bag and I ended up removing it from the, up on top from the throttle thumb lever, that way I can keep everything intact. So on the 700's you've got the pulse pump for the carb, goes right into there, runs off vacuum off the engine and then you also got a breather going to the air box. So my next step is I'm gonna get that hose out of the way, pull the spark plugs, get that out of the way, get the hoses, disconnect the exhaust. What happened with this one, it's got 500 miles on it, the head gasket blew so it's actually blown coolant, the Y-pipe here. So you can see how hot that Y-pipe is, I don't know if you can see it in the camera here, oops I'm trying to get a good shot, there you go. So the Y-pipe got hot and it actually warped and coolant's blown out of the exhaust. I did check the oil, there is no coolant in the oil which is a good sign because usually the water pump seal on these go bad, they leak and then leak coolant into the crank case and mess up the piston and the crank. So I'm hoping just to get away with tearing the head off, I'll take a shot and see what that looks like, hopefully the pistons are good and go from there, I'm hoping it's just a head gasket. I've got another 700 over here that I got torn apart and it's the same deal, overheated the head's warped, the rest of the engine looks good, oh and the water pump seal as you can see right here it's all black, the water pump seal leaked on that one, so I'm going to get on this and I'm going to videotape as I'm going along, that way you guys can see what I'm doing and once I get the head off, I've got the head shaved, got the new gasket already, get that put back on and hopefully get this bad boy fired up today. Alright so I took the rocker cover off and keep in mind those rocker covers are known to warp, they're plastic, so my next step is I'm going to unbolt all the rockers, pull them all off and the rods you want to keep all in order to keep the rockers with the rods so when you assemble them you put them back, the exact same spot they were in. And then I'll pull the bolts off the head, I still got to pull my exhaust and drain the coolant, I'm just working on the top first and then I'm going to raise my lift and it worked out. Alright so I got the head off, the cylinders look really clean, so I'm beginning to believe there is only 500 miles on here. I did label my rockers and my push rods and what order they are in, oh this is front of the engine, I got that right there, tried to keep my bolts the same, I want to put those back in the same order they were in and I want to show you something. So what I've noticed I've got both 700 engines torn apart and it seems like what they like to do is on the exhaust and this would be the exhaust ports coming out, they're very pitted. So if I were to put a head gasket on here and throw this back together most likely it would leak around the coolant ports. I've got the same issue on this one, this is the one sitting on the bench, the warped head. Now this one, this is off a 600 and the casting number is the same, if I flip this over there's a casting number right here, last numbers are 0, 3, 6, same number on here, so I'm going to cross reference the numbers but I think those are the same heads, I mean the head off a 425 is the same for a 500, so I'm hoping between the 6 and the 700s they're better because aside from the valves on this one, this one doesn't have all that pitting right there. So I might end up using this head, I'm going to make sure it's level first and if not I'll shave it down and install it. Alright so I'm about ready to install the head and the head gasket and I thought I'd show you the Polaris manual with the cylinder head bolt sequences and if you can read that it's 35 plus or minus 4 foot columns and then after that you let it sit for a minute and then it's another quarter turn after that. So I got my chug all cleaned up ready to go, make sure all your surfaces are clean, I've got my head ready to go that's all cleaned up and I made sure it was level and what you want to do is you want to make sure you oil the bolts and the washers, make sure they're clean first before you do that but upon installation you want to use oil. Okay so like the manual said, drip them in oil and there's a reason for this, that way they seat good when you tighten these you are kind of stretching the bolt and it also helps cut into the chug while you're tightening everything down. So I like to hand start them and then I'll torque them down to 35 foot-pounds, now I'm going to have to move the engine over for. Alright here we go, one starting in the bottom middle, top middle, 5 foot-pounds plus or minus 4, what I'm going to do is I'm going to put a mark on these bolts now that I have everything torqued down, so I know where my quarter turn is, I do this on the 500's tube because on the 500's the torque sequence is different too, it's a quarter turn and a quarter turn, so basically right now I let it sit for a minute, let everything rest, relax, chill and then I'm going to give each one of those a quarter turn and my head will be tight, here we go with my quarter turn, start the same sequence, so you got all my marks at a quarter turn, now you want to take your push rods, dip them in oil, put them in the same sequence, like you can see I have all my marked right here, so you want to dip both ends and put those in, make sure you line them up with the lifters, I'm going to go through that with all of them, now when I put the rockers on I'll torque them down to 22 foot-pounds, I think it's the same plus or minus 4, so I got her all back together, she purrs like a kitten, it's not blowing any coolant, but as I'm going through the radiator and topping off the radiator it overheats almost immediately and I get coolant spitting out of the overflow tank, so I'm going through the water pump and I just want to double check that that's spun, I can start it up for you, just show you guys for a second, as long as you don't let it run too long, she spins, that's what I'm looking for, I just want to make sure it's pumping, next thing I'm thinking is that radiator is probably plugged, it's the only other thing I could think of because I top it off, let it run for about three to five minutes and all sudden temperature just shoots up and coolant overflows from the top, so what I do is I like to burp the system, I leave the radiator cap off, I let it run, gotta get up to temperature, so the thermostat opens up, the fact that it's bubbling over even before the thermostat opens up tells me there's something going on, my guess is with all them fins in the radiator bent over, there's a good chance this radiator is plugged, I did hot wire the fan, I like to do that when I'm burping the system that way it cools down immediately, that's just something I like to do and then you're also testing the fan at the same point, it's either gonna be the radiator or if that doesn't solve my problem I'm gonna check that thermostat, so that's where I am right now, other than that she purrs like a kitten and it's not blowing any coolant out of the exhaust like it was before, here now I can actually show you that white pipe, so I put a different white pipe in that wasn't cracked or warped because right about here all the way across it was warped and it was spitting coolant out of it, so here I'll show you the one that was on there, you gotta try to fix it you can see he welded it all up when he did this this actually warped, so yeah that's a common problem with the 6 and 700s white pipe cracks, runs lean, gets hot and overheats that might have been part of the issue, the other part of the issue might have been all along that the radiator was plugged and that's why it overheated, so I'm just kind of going through everything, I know that spins I know that's good it's not leaking any coolant so I know the mechanical water pump seals good, so I'm gonna keep searching, I do have another radiator I can try, might give that a shot and see what happens, alright so I replace the radiator, I left the cap off, let it purp, thermostat open up, I got my digital gun here, 70 Fahrenheit, 26 here, 163 the thermostat's opened up, pull through the tank, it's actually sucking out of the puke tank, it's not all circulating it's not overheating, check that temperature, so that's how you do a head gasket on a 700, it's not leaking, also quiet it is, no exhaust leaks by the white pipe that's good, put this bad boy back together, subscribe to my channel if you haven't and I hope you enjoyed this video hit the thumbs up if you liked it and like always till next time