 Let me show you what this bad boy can do. Hey guys, welcome back to another episode of Titanium Man Garage. And today I'm working on a Sportsman 500 HO 2001. So if you saw my video earlier, I'm calling this thing the Rats Nest. I give pretty much everyone in my wheelers a nickname that I work on. This one had Rats Nest in the clutch area, I took the clutch cover off, it was horrible. So I pulled the carb off, the air box off, and there was a Rats Nest in there, that air box just stunk horribly. I think they crawled up and died in there. I also pulled the exhaust off, and there was all guts and just, yeah, it was nasty. Let's just put it that way. And the exhaust, I took that off, soaked it, and I'll show you what I got going on right now. So this thing only has 775 miles on it, believe it or not. So you know what the old saying goes, if you don't use it, you lose it. Well, this was sitting in a barn for a long time. And the guy hardly used it, rolled it hard, put it away wet, and would start one day. And then some critters made a home out of it. So this came in as a trade, and I started tearing into it. I don't know if you can see that cam. That cam looks really clean. I took the intake boot off, they actually crawled up and died in the head. So there's most guts and crap in there. The pole roll broke, so I'm thinking the guy probably tried to start it. The Bendex gear was actually seized up, and this is all rusty and corroded, and I cleaned that up. So I was pretty fortunate, I was able to take some PB Blaster, squirt this thing down, and I got it to move, like it should, not moving good. So you ever wonder what to do with your old gas? I use it for quite a few things actually, cleaning up the wheeler itself, cleaning up the engine and the engine components. So what I ended up doing was I ended up pouring gas into the intake, and I'm letting it soak. It's just all pretty nasty, and trust me, if you were in here right now, it stinks to high heaven because of the most crap. So I'm letting that soak, I've been letting it soak for about an hour, and I went through the electronics, phoned a couple wires were crappy there. The starter solenoid does work. I heard it clicking, but the starter does not, so that must have rusted tight from sitting. So that's the first thing I'm going to do. I'm going to go ahead and pull that starter out, and there's really not a whole lot to it. There's, you know, pull your cables off, pull the one bolt here, the one bolt back here, she pops right out, let's get that Bendex out of the way, and then try to clean this up. Once I get that starter in, I'll try to turn this thing over, I'll put the rocker cover back on. I just took it off because I wanted to see if there's anything nasty going on there, but I also phoned a rat's nest up by the headlight. I took that all apart, I'm inspecting my wires, and that, this thing should clean up pretty good. I'm hoping it will run good when I do get the engine cleaned up. I was contemplating ripping the head off and just soaking the head, just getting everything out and seeing if there's a nest all by the pistons, but this gas soaking trick, I'm going to let that soak, put the new starter in, got the spark plug pulled out, I'm going to crank this thing about a hundred times and try to get all the crap out of there, get that air gun in there, blow everything out, get it out of the exhaust, and pray for the best. If that doesn't work, I'll be pulling the head off. So I wish I could get this to come in in the camera, you can't really see it, but there's a layer of crap down by the valves, we down at the bottom there. So my gas trick didn't work out quite well because there's something, letting the valves stay open a little bit, saw the gas drain into the piston, which is fine because it'll blow out. I'm going to take the air gun and try to blow all that out and see if I can stick the screw right in there so you can see what I'm talking about, I got a bunch of crap in there in the bottom, I know you can't see it in the camera, but there's a pretty good layer of crap, I don't know what it is. From whatever nest the mice had made, it's stuck in there, so I'm going to take the air gun and blow that out, and hopefully I'll be able to get this cleaned up nice. Alright guys, this thing's really nasty, I think I got her cleaned up pretty good, he'll see it now, we can see it, at least I can see the valves, before there was just a layer of crap in there, so that's cleaning up pretty decent, I might clean it one more time, soak it with a little more gas, but she's working. Blew starter installed, blew the gas out of the head, and there's still gas in the cylinder, so we're going to make this thing spit. Let's see what happens. Alright, so now we've got another electrical issue. I got my new carb hooked up, starter hooked up, then run out of a couple cycles to try to get everything blown out, and I saw something interesting. The exhaust is actually sucking in when it goes through the revolutions, it's just kind of funny, so I'm going to have to pull the flywheel off, maybe the woodruff key snapped, the timing is definitely off, because it's sucking in when it should be blowing out, so kind of comical. Let me see what I can find, and I'll let you guys know, what I found out was the rockers on the intake side were really tight, so I went ahead loosened them up, I'm going to go ahead and adjusting them now, I can still get a little more adjusting into them, got to get .006 with the feeler gauge, that's pretty good, I'm going to tighten that down, and finding this happens on a lot of my Polaris's, there's good, and I also noticed the exhaust side was loose, that means the intake valve was opening before it showed up, that's probably why everything was sucking in through the exhaust. You just want a little bit of drag, so you can, that's kind of tight, and I'll do the same thing on the exhaust side, there we go, a little drag there, it's good, I'll do the same thing on the exhaust side, so I give you a little load on what I found, I pulled the pull-start cover off, I pulled the flywheel off, the woodruff key was in the right position, a little FII for you guys, I like to pull the flywheel off to adjust the timing, only because the magnetic force once in a while will try to turn the flywheel a little bit one way or the other, and this way I'm like dead on, so it doesn't move, and then I adjusted my rockers like you saw, and put the flywheel back on, and now she sounds a little bit better before it was sound like it was like going boom boom boom boom, now it sounds better, but I'm charging my battery, my battery's a little low, and I'm gonna fire this thing up, hopefully, seems to be pretty stubborn, it doesn't want to start, so getting a little frustrated, I know you guys have been there, so you probably understand, and it's probably why you're watching this video, but I'll figure it out and I'll let you know, so with the pull-start roll broken and my battery draining, doesn't seem like it's got enough kick to kick it over, and also if you've seen earlier, the starter relay was not working, so I have another one here that I plan to install, I want to show you guys a little trick what what I do, I disconnected the the cable going to the starter, and this is the cable going to the battery, when I hooked up the battery and I hit the start button, I saw a spark come off of there, so it is clicking like it's supposed to, like it sounds like it's working, but I think something fried, so what I do is, because I haven't replaced this yet, but I wanted to see if the starter worked, so what I do is I disconnect this and I jump it, okay, and I got to fire, so you got to make sure the keys on when you do this, but for some reason it just won't seem to kick over, so I'm going to replace that, and so I think there was something wonky going on with this intake boot, so I might replace that, because crank this thing over and it just does not seem to want to fire, so I'm gonna try replacing that intake boot, I'm also gonna try replacing the starter solenoid, it's kind of hard to start it, pull a choke and tap the throttle a little bit to see if I can get it to fire all at the same time while I'm jumping it, so I'm gonna give that a shot first, if I can't get it to fire, I'm gonna have to do a leak down test, because beginning to wonder if there's still crap in the valves allowing it to stay open, just a hair where it won't allow it to fire, so that's where I'm at now, I'm getting a little frustrated, normally I'm pretty good at these, I can get them running pretty pretty quick, I can usually figure out what the issue is, that leak down test shows there's a lot of air rushing through the valves, then I'm gonna end up pulling that head off, because there might be something stuck in there that's letting the valves stay open, because I did get it to pop and it did backfire, so it's telling me it's running lean, there's air coming in there that shouldn't be, so that's where the intake boot is making me wonder if that's the issue, so also I'm beginning to wonder if this engine was replaced, the prop shaft in the front, the U-joints were shot, also it can wiggle as the rear bearings are shot, so I'm gonna have to replace those, this is the prop shaft, you guys are wondering what I'm talking about, the other one the U-joints were shot on, I already just replaced that, tire rods were shot, I can move this, so I'm beginning to wonder if somebody swapped the motor and put the speedometer on with it, I mean the cam does look really clean, the engine does look like it has low mileage on it, but this wheeler looks like it was pretty beat, so it's beginning to make me wonder, you never know what you're gonna get when you buy something, so you know it said 775 miles on it, who knows what the guy did this thing, he did a motor swap and threw the speedo on with it, for all I know this thing could have 5,000 miles on it, the way the bearings look and the tire rods and the prop shaft, I don't know, this guy did some plowing with it, so I doubt plowing with only 775 miles would have made everything go like this unless he did not maintain it or lube anything which kind of looks like he didn't, but yeah, it's making me question how many miles this thing actually has on it, alright, so I got this replaced, I swapped it out for another old one I had laying around, now I'm gonna hit the key, so fire over, so that's one issue out of the way, next is I'm gonna try that carb boot, replace that intake boot, still backfiring, so sucking in air or it's loading up with fuel, one of the two, so I'm gonna check that out, alright this might not be the best way to do leak down test, but it works for me, I'm hooking out air to the cylinder and I'm moving the flywheel around to see what I get, that's our top dead center, air should be coming out of the exhaust, the weird part is when I turn the flywheel this way it's supposed to open the exhaust valve, I turn the flywheel this way the first thing that happens is the exhaust valve's open and I'm getting air sucking into the intake, I had adjusted the valve lash, makes me wonder if there's something going on with the valves themselves, that's why this thing probably isn't firing up, the valves aren't closing like they should, I think I'm gonna check the valve lash, double check if anything moved and then try this again, alright guys so this thing has become a living nightmare for me, I did the leak down test and at first when I did it I put a little too much air pressure in it but usually you need about five to ten pounds of pressure, I've got air rushing out of the intake and exhaust so it's telling me that there's an issue with the valves, so instead of me talking and going step by step with how I'm gonna tear this thing apart, I'm just gonna go ahead and tear it down and I'll leave links on here, I have different videos on how to take a head off and all that other happy crap, so I'm just gonna go at it, I already got my hoses disconnected so the cool unstrained, I got my springs off the exhaust, so I'm just gonna take the exhaust off the carb and go to tone and start ripping the head off, let's see if there's something going on with the piston or the valves, I'm thinking the valves are my issue, so I'm gonna go at it. I'm going to add my throttle lever disconnecting up here ready, let's see if I pull the carb up, let's see if I can rip this thing down, I didn't take the boot removed. I don't know what you want to call it, if that's carbon or what that is, a lot of crap on the piston, valves, oh my god they're so crusty, could be why the valves aren't closing all the way, yeah I'm gonna take a pulse to look at that, see what's going on, maybe clean the top of this off, you, you look like carbon, it looks like rat crap, see what's going on there, actually might pull that jug, just to see what the rings look like seeing them this far, you got the hose clamp disconnected here, got the well lines disconnected on the other side, alright so that oil ring, the piston's still nasty, something made a nest in there, cylinder rings are shot, so I needed a piston, so do that, clean off the valves, probably wasn't getting enough compression, go ahead and take that apart, go to town, alright so I'll show you what I got, this piston is all gooped up, the rings are stuck in, they don't look burnt, actually wondering if it was from the most nests, you can see the oil rings all caked up full of mouse crap, kinda wondering if I could just let the soaking gas clean up, put it back together, but I do have another piston, so I think I'm just gonna go ahead and throw it in, yeah I've never seen that before, it's weird, so that was my problem, thought it was the valves, I was getting compression, but not enough, so there you have it, I had this engine laying around that I had rebuilt, and what had happened with this one was, somebody had bought the crank off eBay, actually it was somebody that I got a four wheeler from, he never rebuilt the engine, so I took the crank, put it in this case, and built the engine up, and wouldn't you know it, the crank is bent, so I pulled the motor out and I put a different motor in the wheeler I was working on, so I'm just gonna strip this down, use it for parts, got a brand new piston in there yet, the valves are really clean, I'm gonna go ahead and use that, use the piston, and it's got a brand new timing chain, so I'm gonna go ahead and install that right away, and we'll get this bad boy fired up, one new piston and cylinder installed, I'm gonna keep working I got my head gasket on, alright, put the nice clean valve on, that can take a little while, dip it in the bolts, go ahead and throw them in, what I do is I snug them up, that'll go through the torque sequence, got my snow from the chain, on the chain there are different colored links, normally the lighter colored link goes on the bottom, the two links on the top, go with the two dimples on the gear, go ahead and fish this in, look my test, timing right where it needs to be. So there's two off-color links at the two dimples there. And then down at the bottom, timing mark. And off-color link down there. And you have all that lined up, your key, everything all goes in a line and you are straight at top dead center. So I'm gonna go ahead and tighten that down, put my rockers on, put my chain tensioner on, get this bad boy button up and maybe I can get it fired tonight. Ooh, she's looking pretty. It's gotta put the intake and the exhaust on, put up the fuel lines. Those things should be ready to fire. Let's see how she runs. That was pretty quiet, actually. I needed a new throttle cable. That's a rat's nest in your piston. I had to tear this whole thing down and rebuild it. So it's pretty quiet now, so. Hope you liked this video. Hit the thumbs up if you liked it and like always till next time.