[img]i/expressions/face-icon-small-disgusted.gif[/img]I have a customers 96 500 in my shop with a complaint of a "flat spot " in the starter.What I thought would be a simple starter rebuild has gotten ugly. The starter,relay and battery all check out. The shop manual directed me to the compression release if it still does this.I pulled it apart,checked the valve adjustment,the shaft,spring and ball in the cam all seem to be within spec-however,even with holding the weight in the decompression position as I rotate the cam,it won't crack the exhaust valves open.It only has 560 miles on it.Is there something I'm missing? Help me please!

 

Look at the face of the rocker arm that contacts the ball. There might be a groove in it not allowing the release to open the valves.

 

[img]i/expressions/face-icon-small-confused.gif[/img]Are these rocker arms known for wearing a groove in them? I have heard of some of the early cams being soft.Thanks for the suggestion!

 

Some of the early cams only had one lube hole for the exhaust and the new ones had two lube holes. Not sure if they were soft or not. Some would last 6 months, some would last 6 years and some never had a problem.

I have seen grooves in several rocker arms. I have seen several without grooves. Just something to check.

 

Has Polaris warrantied the camshaft and rocker arms for the oiling issues? Also, if I replace them, should I order parts for a later year or have all the cams been updated with two oiling ports?Unfortunately, I had to put the machine together and let my customer take it to plow with, so I haven't been able to check out the damaged rocker arm theory. Should come back to my shop later this week.Thanks for the input!

 

It won't get covered under warranty if thats the problem. The cams all sub up to the newer one so you won't get the old style cam.