HELP! Magnum 500 Carb/Electrical Problems!
#11
#12
Groove in the plug is normal.Green wire is low beam headlight power wire. Brown wires are ground.Just down load the pdf sevice manual link I showed and look at the wiring schematic,Or just get a hard cover manual from Ebay. Can make something complicated simple if you just study the manual,plus shows about the cam specs,valve adjustments,carb,etc. This for up to 98 models,but wiring and specs,carb are the same.Index of /ORV Manuals/Polaris/1996-1998 - All Modelshttp://www.ebay.com/itm/Clymer-Polaris-Magnum-Big-Boss-425-500-Service-Repair-Manual-1996-1999-M362-2-/190815570127?pt=Motors_Manuals_Literature&hash=item2c6d7e88cf&vxp=mtr
#13
Here's a successful update! I ended up changing out the Spark Plug because i didn't like how it looked. As Old Polaris tech told me to read the manual alittle bit more, i did so. Doing so, i realized that the Pilot screw was ment to be 2.5 turns out. When i checked what it was(i set it to what it was when i got it), it was COMPLETELY SCREWED IN. So i put it back together and used the pullstart. Started first pull and idles great! Im going to read the manual alittle bit more but this is only one more issue. The dash lights up with the speedometer, but the Electric Started, lights, Winch, 4x4 switch doesn't work.
#14
#15
Put the air box and filter back on and it should run better.Check the cam also for any wear on the exhaust lobe.Very noisy on the front clutch. Ramp buttons probably worn down to nothing.If the slide area on the clutch sheath where the ramp buttons glide is deeply grooved,the clutch may need to be replaced if ramp buttons don't solve the clacking problem. This noise is from the spider hitting the clutch. Inspect the area to the right of where the pencil is in the picture.
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