2002 Polaris Sportsman 500HO
This is reposted, there must have been some words said between some parties and the web master or some1 locked up the old topic. Well here we go again.
I have installed my dial a jet and its blowing fuel out of the hole, doesn't matter what hole its in and when you first rev it up is when its doing that I can tell. I called Thunder Products and said it may be a intake valve being tight. I have only 570 miles on it and was told at the dealer that the valves didn't need adjusting till around 1500 miles. I know they said it might look wet around it but I know it should NOT blow fuel out under throttle.
I removed the plug and I have a compression gauge,I can also pressurize the cylinder at 120 psi, There is NO air coming out of the intake or exhaust. On comperssion stroke. SO that rules out valves, I can turn the crank over (Ihave the clutch cover off) and hear air out the intake and turn it over again then it comes out the exhaust another turn and it stops on compession stroke. I have work on cars before I have a little schooling.LOL
I went ahead and adjusted the valves, removed and pluged the mod air box,no sticking valves,and still blowing out the dial a jet. I can remove the fuel line going to the jet and the fuel bowl is not pressurizing because the fuel is not coming up past the fuel level running it . SO thats right and that means the carb is ok. What could cause the intake to blow back if thats what it is. If its a sticking valve there would be a performance problem.
I have pics showing it.
I have talked to Thunder Products and have been very courtious and are trying to help,I could easy take it off and do a reg jet, but would like the benifits from it, I have changed jets 2 twice to stop this problem, SO ANY THOUGHTS. Nice thought please.LOL I hate for this to lock up as well
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to me it just sounds like a malfunctioning dial a jet module. dunno if there is a seal inside that could be broken?

i have a dial a jet as well that i am waiting untill spring to install . this interests me because i want to make sure that i dont run into the same situaition. i have read the instrucions a few times since reading the post. i cant really think of anything why it would do this. weerd.

thunder products didnt offer any other solutions or ideas, other than the valves?

X

 

Not really, I have ran test and changed things all weekend and today,cylinder leak down test,air test at 120 psi in the cylinder with no air leak at valves, adjusted valves, checked for valve sticking, I knew the engine was good but I know now without a dought the engine is good. I removed the mods to the air box and plugged it,placed the stock air filter back on and removed the two vent hoses to the air box.The only thing else he knew to try was to send 2 different size mixing chambers for me to try,they will have different holes (smaller)in the brass tube. The onlything iv'e not done is removed the ehaust and put stock back on,too much time and money to leave off.The guy said he has been in the dial a jet ?business 15 yrs and not seen this before. He had me to change the carb jets,Iwent down 1 size then another and still done it.
I should have gave along time ago,but If the new needles doesn't fix it then he will give me my money back.

 

i cant beleive that he didnt at least offer to send you a new module or something!!!!

i think you have more than bent over backwards trying to make that thing work. if your quad ran great before, theres no real reason i can think of that would cause all of these probs, other than the dial a jet unit it self. quite strange i must say.

X

 

I can't belive it either, I was hoping a new 1 all together to end all dought of what it is. If its the body itself how will I know just by putting on new mixing chamber as he calls it. Well at least he said he would give a full refund.Does't make me feel any better after all weekend of working on it. Our group had a big ride Sunday,but not me. I am afraid to ride it in the yard, Its liable to explode.[img]i/expressions/face-icon-small-shocked.gif[/img] I will give it 1 more try with the parts,but the 1st sign of fuel im jerking it off and sending it back and doing a reg jetting for the mods. All this time of BS and I could have figured out what jet I should have been running.
Im sorry but I just can't see it being the quad,unless someone proves me wrong.

 

Well, here I am again. It was still doing it. I sent it back and they refunded the part but not for shipping either way so I was out around $20. That should have been refunded as well .At least paid for the shipping 1 way anyway.IMO. Well I have it running now and runs great after going to a 160 jet and dropped the needle to the lowest setting. With a mod airbox and Big Gun pipe.
The only thing that the guy at Thunder Products said might else cause it was the Exhaust system but there is to much trouble to put the stock back on. Oh well I learned a lesson for $20 I won't recommened it for the reason of all the work I did and didn't get a shipping refund. So much for customer satisfaction.

 

thats too bad man,,,sorry to hear all that.. your the only one that i have heard that had probs with that dial a jet.

im still gonna install mine this spring,, hopefully all will be ok.

X

 

So what do you think of your Big Gun exhaust? I just ordered one for my KLR650 enduro, the Quiet series....and a jet kit and K&N filter....have to break it in first, and then will install the stuff and tune...

 

Well I like it so far, this is my first perfomance pipe, out of all the things I had before, this is the first one that I could afford for a quad or a bike. Has good looks and sounds great. I really can't say as far as the perfomance due to all the mods that I did at the same time. But id say it gave it some though. I ordered mine though Pats Small Engine a website that was several $ less than everywere I checked.