The main difference between your engine and the 500HO was basically the higher duration cam and the 40mm carb. The head,valves,piston,etc are the same. The HO engine came out in the 99 Scrambler 500 and in 2001 on the Sportsman 500. Only difference between the HO cam and yours is the duration. Cam lobe heights are the same on both cams.And yes you can make it a HO by changing cams,intake manifold and the carb,but can get a little pricey.

 

Ok so today I installed the starter. Still on the old coil and starter solenoid though. Had it running but as soon as you rev motor up it acts like its choking.

Wiring is a mess but this quad has seen water don't know about a lot of mud but the flywheel housing did have water build up. But the clutch is clean as a doctor office. Little to clean for my taste. Something off here been reading on a ebs seems this set up won't fit needs just be a pain later on. Was reading about switch on primary and secondary clutch and two way.

Anything I might be missing. Guy told me before the rear would seem to lock. Why I was reading on ebs. But the smoke from carb when it chokes off is where confusing kicking in. He also mention he had to hold the override forward. Guy claims he worked on polaris but 96 I know they changed a lot. Any ideas?

 

If the stator/flywheel area is clean,you've pulled the black wire from the limiter module,if you've eliminated the carb as a problem area,then pull the cam cover and inspect the cam exhaust lobe for wear. If it's still popping back through the carb this is one of the symptoms of a flattened cam lobe.http://forums.atvconnection.com/pola...d-cam-pic.html

 

The 1996 and 1997 500 Sportsman are the only two that had no CV rear axles ,they were u-joints only.
My dad bought his 97 new and its the most noticeable difference between his and my 2001. I think 97 was the last year of the cable analog speedo, then they went to the by wire wheel sensor digital speedo.

 

I will take a oicture of the rear to me looks like u joints.

Found the limiter is on the grill will also take a picture wierd place only one with black wire and unpluged it took off in reverse even with bog prob.

Am going to record video. Its wierd almost like the valves need adjusting. Something telling me in the back of my mind clutch. Its auto I haven't felt it shift and in reverse acts different. I will use my liquid image goggles for good pov

 

On the early Sportsmans' the limiter is on the frame. The regulator /rectifier is mounted by the grill. Just pull the black wire from the limiter module. You should then have full power in reverse and awd without having to push the over ride button on the left control switch.This is a cvt system. There are no shift points just a smooth continuation of power. Down load this pdf service manual so you can understand this machine better.Index of /ORV Manuals/Polaris/1996-1998 - All Models
Here's the location of the limiter and reg/rectifier.#34 is the reg/rectifier.#32 is the limiter,but not listed.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Yea I have pdf am going to take few pictures and video. Besides cdi there no other box with black where. There is a brown. I will record video am sure seeing what happens could help in finding out what issue could be. About to make a video brb

 

Its easy to tell. CV axles have the CV joints hidden inside black rubber boots at each end of the axle.
U joints are exposed so you can grease them with a grease gun once in a while.

 

your right

 

i believe exhuast lobe is bad going to make a video today.