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So I have my 2003 Scrambler 500 4x4 finished. Painted. Wiring sorted and changed seals and bearings on left front hub. Had no oil in it. Did a full service on it.
While it was in the shop waiting for the hub seal to arrive (waited a long time and they actually sent the wrong ones so I had to wait some more) I did what seems like a popular mod online. Cut the back out of the original muffler, put a tail piece on it and cut off the original tiny elbow that came out the bottom. Sounds great! Now it seems some people say you need to change the jets after an exhaust mod. Is that true? Also made a new front bumper as the original one was bend.
Last edited by DennisZ; Feb 19, 2016 at 02:20 PM.
Reason: Typo and added pic
only way to really tell is to look at your spark plug i think...scrammys were jetted fat out of the shop so u might be good
Most of the time on an exhaust change only,jetting doesn't have to be messed with. Occasionally an adjustment on the fuel screw or needle clip position change might be needed if it hesitates or bogs. What most people don't realize is that a less restrictive air filter system affect these machines more on jetting than an exhaust system alone does. Pull the air box off a Sportsman or Scrambler and they don't run worth a flip as jetting is tied in closely to the filter and air box being installed.
what are those metal looking things coming out of your front fenders? never seen that before
Don't know. Maybe to fix a front rack? They were there when I bought it.
Why is my bike spewing water out of the little vent hole, under full throttle? Looks like only when cold, the other night I tried that LED light, on a sandy part of our farm. Drove for an hour or so never got hot. Next morning I topped of the radiator, was just below visible. When I rode from my house to our farm I drove slowly, only to rev it hard once and when I did, my pants was wet. Been driving all day no overheating.
If your talking about coolant spewing from the over flow bottle,then sounds like trapped air.On many machines best to raise the front end.leave the cap off and run the engine until the fan kicks on and off several times to purge air. Top off the radiator and overflow bottle and then see how it does. Plus look under the water pump area for any signs of coolant leaking. If there is could be a water pump seal needs to be replaced.
If your talking about coolant spewing from the over flow bottle,then sounds like trapped air.On many machines best to raise the front end.leave the cap off and run the engine until the fan kicks on and off several times to purge air. Top off the radiator and overflow bottle and then see how it does. Plus look under the water pump area for any signs of coolant leaking. If there is could be a water pump seal needs to be replaced.
Fan is hot wired, temperature switch must be bad. Haven't connected the switch yet , might actually be working but I doubt it. The previous owners had the bike to pull tarps under the olive trees when harvesting. So not much driving. So they may have hot wired the fan to be constantly on.
But I can see where this bike is not suitable for that. Way to much power. If I can do a wheelie with it imagine strapping some tarps to the rear rack. (Not to the tow ball, there were some steel tubes welded to the rack!)
Wells SW526 is the sensor. You would have to cut your connector off and reuse it to match up with your wiring harness but no big deal. You can get these at any auto store,ebay,Amazon,etc. Whoever has the best price.It fits all models that take Polaris Part #4010161 including yours. Even Caltric has one for 26 bucks on ebay..http://www.ebay.com/itm/COOLING-ENGI...JWLqDU&vxp=mtr
Feb 19, 2016 | 02:08 PM
Do I have to change jet after exhaust mod?
Most of the time on an exhaust change only,jetting doesn't have to be messed with. Occasionally an adjustment on the fuel screw or needle clip position change might be needed if it hesitates or bogs. What most people don't realize is that a less restrictive air filter system affect these machines more on jetting than an exhaust system alone does. Pull the air box off a Sportsman or Scrambler and they don't run worth a flip as jetting is tied in closely to the filter and air box being installed.
