I just bought a 1996 polaris sportsman 500 a few weeks back. it had no spark so I had the stator rebuilt by rmstator and now it has spark. unfortunately the idle had to be turned up to keep it running and if i give it more than an "idle" amount of fuel it will sputter, run like crap, and not move faster than a brisk walking pace?? I am going to clean the carb today but not sure if this is indicative of valves, top end, carb, or ?? i put a brand new plug in, fresh fuel, and a new needle/seat as the previous owner said the carb would fill up with gas if you didnt turn off the gas?? Air filter needs replaced but even with it off it runs the same?? What should I check??

thanks

 

Compression ,Cam shaft condition is what I would check.

 

<div class="FTQUOTE"><begin quote>Originally posted by: TLC

Compression ,Cam shaft condition is what I would check.</end quote></div>

thanks for the reply!!

compression I can do....but what am i looking for on the cam shaft? do i need to remove everything to thouroughly inspect the shaft??

 

some years of 500's had worn cam lobes. i think thats what he ment.

 

here's what I found today....

when the cam shaft sprocket is at tdc the flywheel marks are past the inspection hole. It's almost as though the cam shaft sprocket had jumped a tooth or someone had put it back together one tooth off. My question is this now: I moved the chain one tooth so that the cam shaft sprocket is lined up perfectly and the flywheel middle mark is perfectly center with the inspection hole....am I ok now to try and fire it ??? is it as simple as "if they are both lined up" your good to go?

thanks for any replies...dont want to mess anything up. Cam shaft looks nice and shiny so i think its ok. two valves need a slight adjustment so im out to do that right now. thanks again for any input

 

make sure the valves dont hit the piston,if your playing with the timing chain

 

Make sure that the piston is at TDC (top dead center) on the compression stroke when you check or set the timing visually.

 

<div class="FTQUOTE"><begin quote>Originally posted by: Mongrol

Make sure that the piston is at TDC (top dead center) on the compression stroke when you check or set the timing visually.</end quote></div>


please elaborate [img]i/expressions/face-icon-small-smile.gif[/img] ... from what I gather the flywheel inside the starter cover has 3 marks. Those 3 marks are suppose to be visibly lined up with the inspection hole of that cover and teh "V" inside that hole. If those timing marks are perfectly centered with that "V" then that is TDC correct? At that point the cam shaft sprocket needs to have the correct positioning as seen here http://rides.webshots.com/photo/1013...7690pwpePjCfVp correct? I just want to make sure I am on the same page. With these two now lined up all valves are open and clearances VERY close to what they are suppose to be. Before the sprocket was one tooth off of being as it should in the above link when the flywheel was perfect.

thanks again

 

Damn, I accidently deleted my longwinded reply, but yes, it sounds like you've got it right. Couldn't access your URL so didn't see the pics.

Just be sure that you turn it over slowly by hand before starting and feel for clunking or stopping.