 So this video is going to be about taking a 425 engine and building it up into a 500 But if you've got a 500 engine and you're trying to put it together Watch this video because the same rules apply. I just wanted to experiment. I had a couple 425 engines later on and a bunch of 500 engine parts and I needed a 500 engine so I Built one out of a 425 If you have a 500 sportsman and you're rebuilding your engine Like I said, the same rules apply. I'll teach you how to build an engine from the ground up You know put the case house together the crank Pistons, I'll show you how to set the timing So please watch the end of the video because there'll be some important tips on What to do after you install the timing chain before you install the engine some pre-loops off also watch for my next video because I'm gonna drop this baby into a Polaris 500 Sportsman and I'm gonna show you how this fires up and we'll see if my test works And I've got a couple guys asked that. Hey, is this gonna work at 700? Another guy said hey, you know he took out three 300 and turned it into 250 and had a lot of power, so I'm hoping the same thing's gonna happen with us, so please watch the video, you know hit like and subscribe and If you have any questions feel free to drop me a line Thanks for watching. So hey today's video is powered by beer Something that keeps you going So here's the deal. I've got a 425 engine 500 engine parts This 425 block was cracked So I got two 425s case halves that are in good shape went clean them all up and We're gonna build the 500 and I'll show you how stay tuned. Okay, so One thing to keep in mind while you're building use lots of oil like Like Put oil on everything while you're building. This is a crank out of a 425 go up the bearings Slide that in there. Nice bearing next you want to put your counter balancer in So let me get you in close here. There is a timing mark right here. I'm gonna turn it like that And when I put the counter balancer in There should be a timing mark Here And we're gonna line those two up two timing marks. They're lined up the next step We're gonna put the oil pump in Just as long as you put it back in the way you took it out You should be fine if the hand started just so I don't cross thread anything. You have shims One shim goes here one goes here And then now once we put that gear on Definitely don't want to forget your shims Clean this up a little bit that there This gear that drives the oil pump Should matter which way it goes on As long as it meshes in with those gears Like so. Alright, normally I wouldn't use high temp red RTV, but I ran out of the black stuff so What I'm doing is I got it on. I'm just smoothing it out. Do you want it gushing all over the place? I got my other case half. That's all clean I'm gonna put a little bit oil in the bearings. I got some oil in there already. It's kind of really with everything up and then I'm gonna Put the two case halves together keep in mind your Your mechanical water pump Seal slides over this. So when you're putting this together, you got to be careful Not to damage it. Never use enough oil More oil you use the better. It's gonna slide on and through here. It's okay All right, so to build this right away. I topped out the center. There's a mark here and On this gear that drives your chain. There's a mark here Go ahead slide that on Keep that lined up right away Put my nut on. Reverse threads Corner clockwise to tighten And then the impeller on it's gonna snug this up and Don't forget to tighten that nut And then there's an O-ring that goes in there. Bring it back to life One assembled bottom in. It's a 500 All right now for the fun part. Let's get that jug on. I got my new piston My new gasket got everything cleaned up I'm gonna slide the 500 jug over the 500 piston on a 425 engine We're gonna see what this bad boy does This is a Piston ring compressor. Let's take it this lined up, right? It actually works up pretty slick The nice part about this is Take it off Pretty slick, huh? There you have it. One piston installed Now it's time to put the bolts in. There's two of them here. I got these four little guys I got my 12 millimeter bolts in And now I'm gonna just take my gun and snug them up and then I'll torque them down and I thought See what the torque specs are for them. I'm gonna torque them down and a crisscross pad. All right the next step we're gonna install that Plastic chain guides in there. Make sure you do that for us Definitely don't want to forget these bad boys because I forgot to put them on before you put the head on. That's a pain So So go here that slides into that notch like so In here and then there's a bolt that'll hold that in place, which I gotta get Okay guys, just a little friendly reminder while you're building Don't forget your doll pins There's two that go here that look like that And there were two down here too. So now this uh head gasket's kind of foolproof because you can only put it on one way There's one small hole The rest are bigger. Your doll pins are only gonna Fit over that. See you can't really screw it up to put it that way. It's not gonna fit We're gonna put this on Now if you guys remember in the beginning of the video I was talking about uh, I'm basically taking a 425 and turning it into a 500 and Putting the 500 jug on the 500 piston Most of the other parts are 425 and everything's matching up perfectly um Everything I'm doing applies to just uh a 500 engine too because it's all similar And I did some research And uh, this is my 425 head I uh did some cross reference thing the cam the head Everything is the same For a 425 it is for a 500. So we're gonna go ahead Put this guy on Gotta watch your plastic uh chain guide And now we're gonna have to go through the Torx sequence, which is a little crazy If you watch uh, if you subscribe to my channel and uh Watch that one video about uh installing a head Um, it'll go through everything I'm about to show you here. I'm not gonna Go through everything. I'm just dropping the bolts in I'm gonna torque them down And I'm gonna put my chain on And then I'm gonna put my rockers on Don't forget when you put these bolts on You want to dip them in oil So I usually like do they got some Oil here a lube creates them Well the torque sequence for the Polaris is uh goofy You got a tight net then loosen it then tighten it loosen it And that's kind of the purpose of this oil Uh, these bolts do end up stretching after you torque them down So when you go to reuse them You want to use oil so Kind of cuts into a little better go ahead and torque these down And also don't forget these two little screws on the side here as well So get everything torqued down Then go ahead put your chain on Get everything lined up I just recently posted a video on uh most accurate way to set your timing chain And uh Like I said, I'm not going to go through everything because otherwise this video is going to be really long You can check out my channel and I'll post links on here too so you can Know where to go See what I'm doing But uh like I said, I'm taking a 425 and turning it into 500 and then I'm going to post a A video of it running so you guys can see this will actually work I mean a lot of these parts are compatible But nobody knows because you look up the part numbers and They don't match well A couple of years ago. I used to work in an engine plant and um What I learned there from building engines is we had one part and three different part numbers for the same part so I like to experiment. I wanted to find out for myself And I think I found that out. I mean You know same part two different part numbers So I'm going to build this bad boy and show you how it runs. All right, let's go ahead and put that chain on And I'm just going to do is weasel it down this way It's one thing that you don't want to do And we want to get that silver link on that timing mark I also have a video of doing that. It's my recent video that just came out Silver link with the timing mark the timing mark on the gear and the two silver links for two indents And the sprocket. Okay, I've got my chain guides on if you guys saw that Next thing I'm going to do is put the chain tensioner on Once I get these tight I'm going to show you my little trick what I do In my previous video. I had a subscriber mention something about the uh Timing chain and the chain tensioner. I had taken the uh the tensioner apart And I always forget to mention these in my videos I always kind of keep an eye on that one of your when your timing issues could be your chain is stretched So if you notice when you pull the tensioner out of the engine that it's all the way out See if I can't get it to do that Push this in and it's All the way out It's maxed out. There's little Little notches on here Then you know that uh your timing chain might have some issues So you might want to replace the timing chain So I'm going to go ahead and take that nut off and there's a spring in there And that'll release the tension on that Then I'm going to go ahead put that back together And then I'm going to put the spring in And the tensioner in that's going to tension up that chain really nice Then I'll put my uh rockers on and adjust them to 0.006 for the valve lash And uh this thing should pretty much be all done then All right, I decided I'm just going to show you guys because uh I've had a lot of questions on that so you said you take that bolt out Press this in That's going to push that in And you put your new gasket and your Your bolts in which I'm going to do right now Go figure they give me the wrong gasket. That is not correct Had another gasket set so We're going to push that in we're going to put that in I lucked out So that happens when you buy uh Aftermarket stuff sometimes they send you the wrong parts I'm going to go ahead and snug that up. I tend to rely on this gun too much but uh, I believe the uh Torx back on out is uh Six inch pounds go ahead shove this in That's going to push that thing out and See if I can there you go you heard a click that's going to tighten my chain up while I'm doing that Sure, it's uh good and tight I think that's a german word So the next thing I like to do Is before you put your uh Your rockers on Rotate this about three times So that tensioner gives it a chance to work It'll push out more you'll get a more accurate reading when you uh go adjust your valve lash So I'm going to do that now As soon as I can find my gloves Now I can go ahead and put my uh Rockers on So I got pretty lucky with this 425. I took apart the block was cracked And uh the cam and the lifters were all in great shape The rockers I should say go ahead and put them on I'm going to double check on that top dead center And then I'm going to go ahead and Take these down There you have it She's all together Chains tight rockers are in place. I just got to put the bolts down Tight them down Put the rocker cover on And uh another thing I like to do before I install this engine is um The player sportsmen they have a reserve tank on the side Well when you do your oil change you're pouring oil into the reserve And it eventually goes through your hoses into your pump Well that means you're starting your engine with no oil in it So before I put the stator on Like through one of these holes here, I'll take about about a quart of oil About half a quart. I'll tip this on its side I'll fill that up And I'll put the stator over the top That way when you go to fire this thing up It's already got oil in it. She's going to be lubricated immediately You're not waiting for oil to come through your reserve tank and through your hoses So keep that in mind You know hit the like button if you like this video hit subscribe I really appreciate you guys watching my videos. Um, you know, I give you guys advice and help and uh Some of you subscribers you uh, you guys know about engines and you give me tips too So it's one way and for both of us. We help each other out Um, like I said, I hope you like this video And like always till next time