Hi guys,

I bought a Sportsman 500 a while back for cheap!!!! the engine was totally gone though. :/ I bought a "new" engine off of ebay. (It was used, but new to me) Polaris installed it and it had a knocking noise.... Not good.... They said it was light and didn't seem to be a major problem. They took it out without my permission, so i didn't get to listen to it. I brought it back home because i'm tired of Polaris. I want to have your help (If you seriously help me, i will pay you an amount i think is fair) I'm thinking i should either install the engine and listen to it. Or tear the engine down carefully and see what's going on.

However, i want your opinion and help. I spent alot of time on this ridiculous fourwheeler and want to finish it.

 

Any time you buy any thing used you take a chance.If you don't have a manual look at this pdf service manual and decide if you have the time,money and patience it takes to rebuild one.Index of /ORV Manuals/Polaris/1996-1998 - All Models

 

Well, i've put so much money into this fourwheeler. I am trying to get a refund.

I do not have 3k to spend on an engine.

I'm going to install the engine, run it and make sure Polaris was right. If it doesn't sound anything like my 2001, i will take it out, shove it up the company's Spam wordSpam word Spam wordSpam word Spam wordSpam word Spam wordSpam word * and just live life. If they don't give me a refund, i will tear it down and see if there's any major damage. I'm even trying to strike a deal with the company to tear it down for me and fix it.

 

Hopefully the dealer can work with you on this. I've run into similar situations at the shop.Keep us posted as to what you find out.

 

I thought i got scammed, but the company said we will figure something out. Call us Monday. Makes me a bit happier.

 

Ok, i looked at my fourwheeler. The Pipe connecting to the exhaust doesn't have the 2 necessary springs. I think the guy may have forgotten about that and accidentally thought that would the engine making the knocking noise. the opening was barely open to make a buh-buh-buh noise.

 

Could be as simple as the missing springs or even a worn head pipe exhaust seal could be causing noise.Item#16. A good hardware store or the dealer should have replacement springs.Hopefully this is the noise you're talking about.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Yeah, i hope so. I finally got the engine installed, but there are a few "i don't know what this goes to" items in there. There's a Gas line and another gas line. (Ones is alot longer than the other and one has a what looks like to be a filter *white thingy*) The engine has been mounted, carburetor has been installed into engine and into airbox. Etc. I am confused by the 2 gas lines though. And two coolant lines.

If you'd like, i could take a few pics.

 

See if this helps on the fuel lines. #1 hose on top of the fuel pump goes to the fuel valve. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

That didn't help because i couldn't actually tell which was a fuel line.

Sorry! :/ Thanks though.
I thought i would take a couple of pics of the things i'm confused on.

Be back in a sec.