 Hey guys today we're going to be working on a 2004 sportsman 500 Basically this thing came in a box the story behind this is the guy's kid drove the thing crashes into tree This is all mashed up I know somehow I don't feel it laying outside or what but the motor blew after the kids ran and got dead and Came back the motor was dead connecting route was worn out Don't know the whole story on it basically a thing came in a box So I'm gonna put this together and I thought I'd quick Get a shot of this before I start tearing it all apart got the plastics off remember when I said Everything came in a box. I really wasn't kidding the stator the head Well, there I got a bunch of engine parts in that box back there the flywheel the cover So what I'm doing here. This is that motor. I rebuilt my last video and Because this is going into a 2004 we want to keep all electronics the same. I'm assuming this is off a 90 something because that's actually off the 425 So I'm gonna go ahead pull this out We'll put the O4 stator on and the matching flywheel you want to keep that all together because sometimes the insides are different So I got the front ends together As you can see here when the kid hit that stomp, this is all banged up. They said this is all kinked and mashed So if you ever want to take that bracket off there's Not the bolt here. I still got to tighten those down not bolt here and that Goes into the radiator support also there are two bolts down here that bolts into And then you'll probably have the plastic side shields that that'll come off too. So yeah the front's done So now I'm about ready to drop my motor in but before I do that. I want to make sure that I Get my starter in place because it'll be easier with the engine out of The machine to put the starter in so I'm gonna go ahead do that now. I'm probably gonna drop the motor in I normally wouldn't do it from this side selling the engine, but It's the way the guy that took out a part dead So I'm just gonna try to slide it back in that way. All right, so It did work. It was a pain so now I'm gonna get the Back bolts line up in them holes. So I got the motor halfway in so you got them Holes back there. So we got a line that up with those two holes And then you got your front mount Bolts sticking up while you're doing this make sure you don't pinch your wearing harness for your stator or anything like that So what I like to do is Tighten the back bolts first because that's gonna bring the motor back and then Put the top motor mount on that goes up here, and then I'll tighten the back the front one. Be careful not to drop your bolts in the boot size Put the bolt in the boot bring it over the top. This is your chances of Unstarted Same thing of the other side the last thing you want to do is drop a bolt in your freshly rebuilt engine I've done it before but I caught it. I was able to throw a magnet down there. So learn from my mistakes Though I go so any of this thing came in a box So I'm still kind of searching for parts. You got to look for the The ground strap actually for this, but I'm gonna get one Sturded. Oh, you know when you buy somebody else's project Hopefully they've tagged and bagged everything decent so you can find everything all my stuff came in a plastic bin So I'll be searching Yeah, and your top bolt here will go your ground strap and that'll strap up here somewhere This is another reason why I like to leave that bottom bolt loose because you're gonna want to move the engine back and forth to get This little nut back here With your ground strap on it. Okay, so after I got that motor mounts hooked up. I hooked up my exhaust put my donut in You got my bolts in and Let's go around this side Let me tell you a quick tip So go ahead and put the motor mount on first and then do the boot Because if you put the boot on first and then the motor mount it's hard to get that bolt tucked up underneath there And I just wanted to show you this So you got that anytime you do a motor swap Make sure you have the right temperature sensor in right there this particular temperature sensor on the old four has two wires coming in and The one I had in there only had one So I pulled the temperature sensor out of the other head And I put it in there so that that works I got everything else Hooked up. I got my starter positive and negative Got my clutches Now you get your two oiler hoses down here and always keep in mind that You're looking at your oil reservoir. You look towards the bottom on the inside There's a hose the bottom hose goes towards the top Inlet of the engine the top hose Goes to the bottom. I bought a four-wheeler once and The motor blew and the guy couldn't figure out why the motor blew after he replaced it Well, he had mixed up the oil lines. So there was no oil going into the engine. So I thought I could point that out to you guys just It's a little reminder. I thought you guys screw that up. I Just got to clean the carb up And she should be about ready to fire up So stay tuned Listen to this baby roar Here's a quick shot of what I'm trying to tell you about Bottom hose goes to the top Top hose from the reservoir goes to the bottom and one more thing Don't forget to hook up to your coolant lines down here and When you go to fill your radiator there's a bleeder screw right here So crack that open let the air rush out once you see a little cool and trickle out close that up Keep topping it off what I like to do is I'll squeeze this radiator hose and try to get some Coolant back up through the radiator and when I go to fire this thing up. I'll leave the radiator cap off make sure coolant circulates and That way all the air is blood out of the coolant system If you get to air pocket in there and you forget to do that. You might have overheating issues So I said I just got to clean the carb up. This thing must have been sitting for a while. This is an H.O. She's pretty crusty in there I give this thing a good cleaning and Once I'm done with that I should be Not ready to go. Hey, so I just got my carburetor hooked up Already get this bad boy fired up. We'll show you what this 425 convert into 500 does So here hold my beer while I pull start it. Yes, it can be done