Lol very true and no worries glad to have found the issue whew I was beginning to get frustrated their are more new parts on it than old parts now lol cam,carb,starter,solenoid,magneto,pickup coil,flywheel and soon exhaust manifold lol

 

Any idea where to find a new rev rpm limiter I will like awd to work

 

Awd will work with out the rev limiter! Limiters main purpose was ignition related and to just retard spark in reverse( was supposed to) and only when you pushed the over ride could have full power. Awd wouldn't kick in anyway in reverse because you couldn't go fast enough.You still have to push the over ride though to get awd in reverse because of the way the awd system is wired.. This place has an over ride kit,but what I've heard on the comments is you still have to push the button for awd to engage. ATV Accessory You've already essentially done that by eliminating the limiter module to begin with when you pulled the black wire. You might be able to do away with the over ride button entirely by this method:

"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 this bother you on cutting wires just use the button in reverse if you need awd..

 

Yah I can live with using the button lol sorry I was thinking I lost awd all together 👊👊

 

You're not the first one to think the limiter module was actually part of the awd system. Hope it holds up for you now especially with all the new parts.

 

Haven't looked at the manual yet how complex is adjusting the valves

 

Simple and you don't have to be concerned with "strokes" that confuse so many people.You can use this method on any 4 stroke. Just pull the cam cover and right side cover on the head,pull the recoil starter over slowly. Watch the intake rocker arms only. As they go down and start to come back up slowly pull the recoil until the cam alignment pin is dead center of the head. This is tdc. Best to have two .006 feeler blades for the double exhaust rocker arms. Just slip one under one side(loosen the lock nut and adjuster if necessary) and one feeler blade under the other side.Tun the adjuster until there is a slight drag on the feeler blade. Hold the adjuster from turning with pliers and tighten the lock nut. Recheck clearance. If ok go to the other side and do the same. Using two feeler blades is just to keep the rocker arm from cocking or placing it in a bind. Intakes valves you do separately. Both intake and exhaust set at .006. There are small valve clearance adjuster tools out there,but not really needed.2218 6 PC Valve Tappet Adjusting Tool Set for Motorcycles ATV`s and ATC`S | eBay

 

The adjustment was simple thanks for the walk thru running well and of course found an exhaust leak I'm guessing those pesky backfires from early in this project took out the donut so ordered one so we shall see what happens after its replaced

 

These old donuts wear from vibration over time. Worn springs,exhaust gasket also cause problems. Here's a complete rebuild kit that you might look at. 1996 2000 Polaris Sportsman 500 Exhaust Gasket and Spring Rebuild Kit 5240898 | eBay

 

I like it that's a nice kit thx