I cannot tell you how much I would appreciate you smart riders out there with my problem. here it is! I have a 2002 sportsman 500 HO. It has 1300 miles and 90 hours. After riding even a short distance i.e. 20 miles I have oil in my air box. We have replaced the check valve and after 800 dollars replace the sump pump. It has great power and runs wonderful except that the oil is dumping into the air box. Polaris customer service is a big joke and is no use. If someone knows the answer and helps - whenever you are in Tucson, Arizona - I owe you a dinner!

need to ride again!
[img]i/expressions/face-icon-small-confused.gif[/img]

 

Do u know where its leaking in at. That should be the first place you check. Its prolly something simple but check to see where its leaking in at and start from there. i dont know much bout them but its just logic really. it cant be leaking in from everywhere ya know.



P.S. welcome to the board.

 

How much oil are we talking about here? Have you flipped it or stood it on end lately?

 

 

Does it pump oil non stop in the air box even when its level? If so could be worn out rings, valve guides..

 

Thanks to all that took a shot a my problem. Here is some more facts:
Compression test is great no blow by or leaks
Never have flipped or turned over the quad
I puts oil in the air box even at slow riding on level gound
At 25 miles it is as much as 9 oz's
As you face the quad from the rear - it is leaking in the box from left vent hose. There are two hoses coming into the box as vent crankcase hoses


Thoughts????????????????????

 

Im not familiar with your bike

But check and see if the oil comes from the hose that is atached to your crank case breather port if it is run the bike with the oil filler cap off There should only be a slight breathing from it expect some oil but not much pressure/gas.

Where do the other two hoses come from??

 

Sorry i see you said both hoses were crank case breathers

I take it the oil level is correct and not being over filled i know its obvios but always worth asking

also some motors will have a strainer/separator in the crank breather to encourage the oil to drop out of the air not sure about your bike though.

one more, check that both hoses are clear to the crankcase as if one is blocked it would double the air velocity in the other which woud tend to make it carry more oil with it

All out of ideas for now let us know how it goes

 

yeah i would say to do what they said u also could just take off the seat and air box lid and rev it up at a stop for a lil while and try to see if u can see where its coming from

 

i have got a 2002 400 sportsman
but no problem like that,
i agree with the other guys as well do what they say.
and by the sounds of it you have got a bad chuck velve to keep the oil from blowing up the hose, i would check that for sure.
but being that there is that much oil and your machie is new with a few 1300 milles im sure that it is not blow back past the rings, unless you have overheated the engine bad.