I just put a new Top end, Cylinder, Piston, Pin, Rings, Gaskets, CAM etc. to try and fix a sputtering SMOKEY sportsman 500 but it's still sputtering unless I press the yellow override then it smooths out. I also don't seem to have any reverse or neutral lights. Could be connected improperly

History, Ok I bought this basket case Sportsman a year or so back and it was in pieces and the guy said it used to smoke real bad but ran well. I parked it for about a year to work on another old Yamaha Enduro project but just got back around to it. I replaced the pull start mechanics, Bendix and rebuilt the carb got it running and it ran but smoked and sputtered real bad. Read it could be the soft cam issue so I just ordered a rebuild kit and a CAM. Got it all rebuilt and it runs (Without smoking) YEAH

Issue #1 Still sputters unless I press the yellow override button.
Issue #2 Really hard to pull start or electric (seems to have really good compression) maybe too much. I'll check valve clearance and double check compression weight on CAM. Have to use both electric and pull at the same time to start. Has only run for 10min since rebuild.



What's causing this and how can I fix and or disable this thing.

I still have lots of work to do It needs rear CV bad as it's clicking and popping so I'll work on that while I await some good suggestions

 

First check that you have the decompression arm and spring in correctly. If it's not that can make it a bear to recoil or electric start. If that's ok,then could be the limiter that's in the speedo.If it clears up when you press the over ride button,you may be able to bypass this and see if it helps. Several post on this that may or may not help.Polaris reverse overide switch? [Archive] - SnowandMud.com Being a 2001 model this may be easier."Pre 2003 and almost all models that do NOT have the combined override/Speedo function button.
Trace wires from the override button (gray/white & gray/orange) Cut the gray/orange and tape up both ends. Cut the gray/white and tape up the end which goes to the override button. Connect the other end of the gray/white to the red/white (ignition supplied 12v)" If it works you may(or may not) still have to push the over ride to get awd in reverse. I've heard it both ways from people.