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HELP! Magnum 500 Carb/Electrical Problems!

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  #11  
Old 12-19-2013, 09:30 PM
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Here's a video walk through of the fourwheeler. Doing anything on my end to try to help you guys understand things. Other issue later down the road is the wiring mess.

 
  #12  
Old 12-20-2013, 07:10 AM
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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  
Old 01-05-2014, 08:34 PM
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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  
Old 01-05-2014, 09:50 PM
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Sounds like you need to dig into the clutch and do a little maintenance there as well judging by how much it sounds like its rattling. Sounds good other than that though, especially for the money.
 
  #15  
Old 01-06-2014, 08:53 AM
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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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