Hi guys,

I'm going to buy a 1996 Sportsman 500 that has low miles and doesn't start.

What would be the first things i oughta check when i get it?

I have all the tools and the knowledge to do stuff, but i do not know what the first things i oughta check be.

 

Start at the basics.Check the oil in the remote tank(replace it and filter if dirty) check for spark,clean air filter,good fuel supply to the carb ,carb clean if needed,plus especially on this model pull the cam cover and check the valves settings (.006 intake and exhaust)and check the center(exhaust) lobe for wear.If the cam lobe looks worn compared to the two outer intake lobes this could be the problem? Most usually will run with ground down cams,but pop back above idle when the throttle is applied.Pics courtesy of another member. http://forums.atvconnection.com/pola...d-cam-pic.html

 

Alright, i'll do that.

If i wanted to make it a HO, Wouldn't i change the cam, and carburetor?

I'm planning on replacing the Brake Bar, Tires, 4WD Button (To the newer ones), Add a 4000 viper Winch, Add a Front brush guard, add a back guard thingy, replace the Speedometer, etc. (Of course, this will be done after it runs.)

Does it sound good? I want to update this fourwheeler to keep running.

 

The updated cam(3086212) is still available for non HO models,but you can interchange with the HO 3085855 cam. The head,valves,springs are basically the same,but you have to also change the carb adaper ($37) and the carb is $375 at Cycle Parts Warehouse if you bought one new or take a chance on a cheaper used one on Ebay that you'd probably have to rebuild. I guess it depends on how much you want to tie into it,but to be honest with you, you have the better of the two carbs as far as working on it,less leaking problems even though it's smaller than the BST40. Just my old opinion,I'd get it running and drive the devil out of it,save the carb update for other items such as the winch,etc.

 

Alright, i'll do that.

I bought it for 600 and i've taken the right side out (Looking in the front of it, i've tried to crank it via the pull one, but it's really tight. What should i do?) If you do it via the Automatic one with that battery it just sounds like it trying to turn, but whines instead. If that makes any sense.

 

Pull the recoil cover and see if the starter bendix is locking the flywheel from turning. The bendix can be pulled out of the case. Plus you should be able to turn the flywheel by hand. If it wont budge and you've checked the clutches out,it could be a piston seizure problem.

 

Took everything apart, guess what?

The thing that's supposed to be kicking out to turn the big thing (Lol, don't know the exact names), was misplaced. LOL.

Put it back in. It runs like new!

I bought a working fourwheeler for 400$ (1996 Polaris Sportsman 500 for 400$)

 

The starter bendix was what I thought the problem was from your description. You got lucky and sounds like you made out pretty good on this deal!Doesn't always happen like this!! Now you can spend a few bucks on the extras. If you ever have any problems again with the bendix or starter here's a cheap place for replacements.http://www.dbelectrical.com/c-1804-sportsman.aspx

 

Silicone, the pull rope handle in place so its a water tight fit. There are alot of parts behind the recoil cover that do not like to get wet and dirty.
Stator,pulse coil,flywheel,bendix and so on.

Also that year of ATV has no CV joints on the axles that are sealed with a boot.
There exsposed U- joints and need more attention with greasing.