Thanks X 100 for your posts. Bought an 1999 Polaris for my son and we've used a lot of your video's to fix it up. I was really baffled because we had changed cam, fuel pump, fuel lines and carb, but couldn't get rid of the bogging down and backfiring. My intake boot was cracked in the same location as yours...problem solved. Cam needed changed anyway...same probably goes for the carb and fuel pump.
Brother you helped me out just by saying check your diaphragm. My $38 dollar carb from Amazon was absolutely shit. I was driving down the rd and the little pice that’s on the diaphragm fell off and absolutely made it run like shit. Well I went back out after watching this vid and put my finger over the hole and it completely fixed my issue
Intake boots are a common source of air leaks. Not just on an ATV but on chainsaws , snowmobiles and motorcycles. I use nonflammable brake cleaner to find air leaks. Just start the engine and spray the area you suspect. The instant that spray hits the leak the engine rpms will fall off. Works awesome without fire risk. Also works great for finding crankcase leaks on 2 strokes..
Awesome 👌, just yesterday had to work on my Polaris sportsman 325 would not stay on...took out the spark plug was black and smell like gas... cleaned it out put back on problems solved but did noticed a back fire ...in reverse. I will look into carb hose and also my choke on it is acting up .
I have a question? I have a 1998 Polaris sportsman 500 4x4 I brought back from death. I used alot of your videos by the way great work. But now I have it runnning fine 3 or 4 times and then I kill it and when it goes to start again the crank bearly moves - but it runs fine when has a fully charged battery for a little while. it has a new stator and pulse coil and new head gasket and cam and rocker arms and checked valve to 0.06 and air gap is at 0.20 for pulse coil. Im stumped only thing I can think is maybe the voltage recticfier regulator is quirky. Just thought I would ask if you have time any advice would be appriciated. Thanks. from all the followers of his channel - He does good work and advice is never a bad thing.
Regulator rectifier will keep battery charged. I would check your ground wires. Maybe replace regulator. These 500 need a good battery. If you bought a cheap one they don't last long. Start there. Something is draining the battery. I'm glad you like my videos.
@@TitaniummanGarage Thanks just ordered a Voltage rectifier and CDi to be safe. Watched another video of yours on bogging Polaris and saw some good info on hoses and air leaks and carb to head tube so will check that out tomorrow thanks again for all the great videos and good advice its appriciated.
@@TitaniummanGarage I have a 2006 sportsman 500 HO efi that I bought. It doesn’t start. I checked and it has spark, fuel, and compression. I checked the valves and set them at .006. New spark plug too. Still no luck. Any ideas?
I’ve been trying to figure this out and it sounds like we have the exact same issues. Time to fix the things you mentioned and see how it does. Thank you for this video
A little off the subject... I have a "2012" Sportsman HO 500, with believe it or not, less than 50 hrs on it. Back a few months ago I noticed around 5000 rpm it would bog down and almost die an get that pop pop pop on hills.. It idled and run fine otherwise. Since I hadn't rode the thing very much, I believed it was trash in the carb. I cleaned the carb and replaced the jets.. No improvement. So, I purchased and installed a new carb.. Problem didn't improve. I changed the plug.. No help. I replaced the pulse pump and all the fuel lines.. No help. Removed and cleaned the tank.. No help. I knew the air filter was new, so I hadn't even given it a thought it might be the problem. But, one evening while listening to the engine idle, and revving it a little.. I thought I'd remove the filter cover and see how it run.. and it actually improved a little.. So, I removed the filter, and it improved a little more. And that's when I found the culprit. All that money spent on parts, time of changing them out.. and the irritation of worrying about this bike.. came down to the hard plastic sleeve inside the rubber breather tube, that prevents the rubber from crushing when you tighten the air filter onto the rubber intake hose. When I replaced the air filter, I had invariantly caused that little hard piece of tubing to be turned sideways inside the rubber breather hose.. which allowed enough air for the bike to idle and run half throttle, then fall on it's face around 5K rpm or so. Moral of the story.. Check everything, even if you think it's correct.
I actually believe I did the same thing! Over tightened the clamp on the tube just outside air filter box and it left a big v shaped hole into intake. Ran way better once I loosened it.
I took a little all purpose glue.. the kind that stays flexible, and smeared it around the hard plastic sleeve.. Then slid it into place and let it dry overnight. Worked well!
I was actually thinking of doing the same thing to the intake manifold boot the carb connects too. Put a bit of Flex seal all around it. I don’t think it leaks cuz I tried starting fluid all over it while running and it Nvr reved up. But don’t think it could do anything to hurt it. Only possibly help. I gotta get Mr. Titanium to do a total carb and jet video. Guess that’s one night ce thing bout EFI.
Good videos. You sure know Polaris… quick question. I have a 2000 sportsman 500. Runs good idles good doesn’t loose power but when I let off the throttle sometimes it backfires and even shots flames from the exhaust manifold where it conects to the rest of the exhaust. Could it be my intake boot.? Or ?
As has been talked about before if the common issues checked dont fix the issue check the camshaft for a rounded off lobe on its central exhaust cam , its well known very common issue with this engine and causes bog and backfires as a symtom. , some CDI boxes will fail to maintain proper spark timing and cause backfiring and loss of power if the battery voltage regulator fails and the charging voltage goes to high at higher engine Rpm's.
Are these the same carbs they come with ? I wanted to do an HO carb Do you have videos of setting up the choke ? Also where do you buy your fuel hose vacuum hose etc... I have a scrambler 500 4X4 pretty much just ride it in the snow ... I try and keep everything in good shape I think I have to put a bendex in mine man she makes some noise if it doesn’t start right up I I’m hoping it doesn’t need a flywheel 🙏🏻🙏🏻🙏🏻 Thanks for the videos ...
I go to my local auto parts store for the fuel and vacuum lines. These carbs are identical. I have put a HO carb on. You need the carb boot too. I also put a HO cam in. The exhaust will get hotter so to do it right you might need to change exhaust.. I made a video on carbs and a video on a full build I did changing the carb to an HO with the cam. Polaris magnum 500 brought back to life was the title.
I have questions I hope you can help me. I have a 2001 Polaris 700 is not start I took it to a local shop charge me 1649.00 but still not working he told me he change the wire harness and I ordered a new cab and fuel pump but still not working
@@fajlustshegchannel7809 what is it doing? Does it turn over bit not fire? 700s are known for bad wiring. Did he replace the stator? Check for spark? I could go 5 different directions with this. I would need more info.
Great video why this wasn't shown as first option for my search I can't imagine the exact year with the exact problem and this was at least the 10th time I searched the same exact thing over past couple of years and this is the first time it ever showed up from search anyhow first time I've saw the exact four wheeler get worked on thanks
I have a 2000 scrambler 500 and it is very hard to get stated and once it does start it won’t idle and runs rough won’t take a lot of throttle Boggs backfires at times and power comes and go’s but mostly only puts around. And dies then won’t start back.I’ve replaced the fuel pump took the carb apart cleaned it best I could. The starter button is kinda messed up too but works. Took the valve cover off and the exhaust lobe looks to be ok.I don’t have a lot of Polaris experience but built many many Hondas and Yamahas it wouldn’t run at all when I got it but I’m rather frustrated at this point. Not sure what route to take.
I have a 2008 Polaris sportsman 400 HO . It sat for years ,only has 30 hours on it and it's 13 Yeats old ! A Polaris dealer put a battery in and air filter for my friends widow. Charged her 500 bucks and gave it back ,it started but ran like scrap ! I found 2 clear plastic tubes up under gas tank plastic cover that were not connected to anything ! I blew in the hose and could hear gas bubbling in the tank? So I tried starting it and it ran better when I did that. Soon as I stopped engine would bog!I put a bunch of Sea Foam in gas and it started running better ! Every tank running better ! Out of nowhere it all just start dying out unless you put choke on to keep it running! Sometimes runs with no issues at all and then it will start bogging dying out.It can run for hours without issues ? I also found the thick tube coming from engine to air box had that plastic filter thing melted from hitting the exhaust at one time! I saw you talking about the vent lines to the air box being important and wondered if that could be the issue. Also can't figure where the two smaller clear plastic tubes on top of tank are supposed to connect . They just lay up there open ended.
The tubes on top are the tank vent hoses. If they are blocked it will cause gas not to flow. So you did the right thing blowing in them to see if they are clear. That plastic filter that is melted would most likely be your problem. Not sure why its on the exhaust side. The vacuum hose from air box on exhaust side goes to top of the oil reservoir. The tube from the engine with the filter goes up the PTO side of the engine into the air box. If its plugged/melted it will cause your condition you described. I would clean the carb as well. The jets might be dirty from sitting. Seafoam is your best friend but won't unplug jets.
My Sportsman 400 is having issues like this it only runs good when the air cleaner is off I went through the carburetor and cleaned it up nothing was really in the carb so maybe when I get home tonight I'll look at the intake
Mine was because of old fuel. I siphoned everything from the tank and put some seafoam ( A little more than recommended lol) then filled it with new fuel. I had to rev it for probably 10 minutes all together until the new fuel finally cycled through and cleaned everything.
I have a 1995 Magnum 425 that runs great other than… from a dead stop it will rev out just fine, but after about 2 seconds (with the engine still under load and over 1/2 throttle) it will bog down. There’s obviously enough gas off idle, but I c ant figure out why it wants to bog under load. Override switch makes no difference. Carb is perfectly cleaned and needle clip is set in the middle. Carb boot is brand new. And fuel pump is brand new. Maybe it’s a vacuum leak from the carb to fuel pump? I’m out of ideas.
@@jeepsandfarming ok yeah, I think I’m going to sell it too, i had just fixed a big exhaust leak a couple days ago and first drive today and it broke again. This model feels like it’s cursed or something. We’ve put over 2k$ in it in the past year and we never even got one full drive in before it broke down
So Jedi master of Polaris wheelers. I watched your “bogging video” I bought one of the cheap Amazon carbs and checked the intake for leaks with starting fluid. Got new air filter and replaced plug and fuel line. Got a fuel pump with carb but didn’t put it on yet. Anyway the main jet on the Mikuni carb was a 142.5(0-3000’ elevation) but it’s it’s generally ran pretty well at 6k’ (my house sits at 6280’) anyway the new temporary carb (while I rebuild and clean up mikuni) came with a 145 and 180 main jet. I put in 145 but in Haynes/cylmer says at higher than 3000’ I should be using a smaller main jet. So I ordered a 30 pack of jets and needles and all that. It runs great with the 145 in till I get passed half throttle then it falls on its face. So should I put in a 142 or 140? If you could do a video on proper jetting procedures(like I said I got 10 main jets a bunch of longer, different ones that I’m not sure what to do with plus 2 other different styles). Id be more than willing to pay you thru Patreon or even Venmo! I’m just at my wits end! It’s a 96 I got for helping sister move. But I have an opportunity to buy a 2002 HO WITH THE EBS, for very cheap but it’s sat 4 yrs+. So I know I’m going g to have to go thru all this carb cleaning and such stuff with it as well. But I don’t want to buy it u til I got the 96 to where I can at least trust it to go off road(on road only now in case I gotta go tow it home, since I live up in the hills. Thank you for sharing your excellent knowledge with us less talented DIY’ers! Plz consider jetting/jets video! You humble fan always! 🙏
Love the comment! Thanks. Hmm... smaller jet? With the vaccum operated carb and higher elevation I would have thought a bigger jet. Let me research that one.
Thank you so much. Now I hope it’s smaller tho cuz I just went from the 142.5(mikuni) to a 145(Amazon) to a 135(but can easily switch to 140 since I haven’t put anything back together yet.
Minimprover 30PCS Carburetor Accessories Kit,10 Pcs Slow Pilot Jets and 20PCS Carburetor Main Jets for PWK Keihin OKO CVK KOSO PE PWM Minimprover 30PCS Carburetor Accessories Kit,10 Pcs Slow Pilot Jets and 20PCS Carburetor Main Jets for PWK Keihin OKO CVK KOSO PE PWM This is the kit. All I was after was the “main jets.” This is why I wish a smarter man like you would do a video on these carbs, mikuni sand Amazon/Ebay Chinese models. Right in line with main jet I thought the long skinny jets may go. I got a screwdriver just to check it out n the brass sides stripped without jet even budging. I’m talking the Lil one inside the bowl, not the 1n 1/2 turn out one, that is outside the bowl(1 n1/2 turn out from tight on 96-97, and 2 n 5/8 turns out from tight on 98+(according to my Cylmer maintenance book). So plz help. Thanks Yoda!🤣😎👍🙏
I need some advice I just bought a second 96 sportsman 500 and it smokes a lot and has almost not power if you hit the gas but idles fine I’m sure it needs a new piston but the rocker arms have some side to side play do you think it will need rockers and a cam or is it possible that oil is leaking into the cylinder from the valves causing the problem
Black or white smoke? Black would be oil ring or valve seals. white would be blown head gasket. There will be a little side play. I guess it depends on how wore the rockers look and check cam lobe height to see if its in mechanical limits.
I just replaced the exhaust donut on the pipe and it already burnt it up. This is a 1999 polaris sportsman 500. Should I just put another donut and put extra springs on to keep it from moving?
@@TitaniummanGarage it is the original mikuni carb and I so think it's running just a little bit lean because it backfires when you let off the gas after revving. But I found out the donut springs are stretched after 22 years so I'm going to get some new ones and a new donut
Hey man, this is the channel I've been looking for ! I've got a 05 500 EFI that runs ok for a while then bogs down and dies. I checked the plug and air filter. Ran some BG and heat and changed the fuel filter. got better but still dies. I finely put a new plug the other day and I know, should have done that first, and it ran like new... for about 2 hours, then did it again. any ideas ?
I would try a cooler spark plug first. If that doesn't help it could be an issue with the fuel pump or wiring. Check for soft wires that may have heated up from riding.
I have a 2016 polaris sportsman 570 spins over and backfires through airbox but when it starts it won't idle until it warms up then it runs and starts fine
hi I have a 96 polaris explore 400 starts up and idles, but when u hit the throttle it dies , didnt check the throttle cable yet or fuel pump. any other idea's ????
I have 1994 Polaris 2x4 300 2 stroke, I’ve cleaned the carburetor so far, but it start up fine and runs about 200 yards and then bogs down and shuts off. I give it like 30 seconds and does it over and over again. What do you think I should replace to start off with ?
I have 2 2005 sportsman 400s and they both bog down and sometimes back fires when giving full throttle. When you go 1/4 to 1/2 throttle they seen to be fine just going from 1/2 to full throttle they bog down and don't wanna make any power. What should I check
It sounds like you need a carb clean..do you use fuel with ethanol in it? Its horrible for the carbs. Gums them up. The next I would check is the timing and if the cams are worn out.
Can anyone help me with my 2001 425 expedition. The transmission is locked up the rest of the atv is in great shape it be great if someone has tackled this and has some advise. Thanks
My time is worth my money, thats why i rebuild the oem whenever possible, otherwise youre paying $40 per year per machine, plus you have to take off the front plastic and gas tank on these to get to the carb. If that doesnt work then ill go cheap ebay carb.
I have an 01 sportsman 500HO, mine does bog down but only sometimes, doesn't matter what position throttle is in, it will eventually go away on its own, any suggestions?
Could be a couple things. Check the carb and boot. I would also try the cdi. Maybe try unplugging the black wire. I had a 2000 that the cdi would sometimes work and sometimes not. If the black wire trick works then you know it's the cdi. But I would check the diagram on the carb and clean the carb first.
I have a question. I have a 2004.5 sportsman 400. It has an issue where it bogs down and loses power only in high range, low and reverse are fine. It does it only going up a hill under hard acceleration. I can drive on flat ground at full speed no problem. But when under a load if you give it full throttle from a dead stop it bogs hard and you have to let off and then it comes out of it. I have replaced spark plug, plug wire, coil, cdi, stator, rebuilt carb, new air filter, new buttons on secondary clutch, new belt. Still no luck. Any ideas would be greatly appreciated. Thank you!
Check your air lines to make sure nothing is pinched or leaking. See if the one way valve on air line is not clogged. also check to see if your fuel lines are soft. If so they can collapse under vacuum. Another thing is to check to see if your running rich on the carb. If you take the airbox cover off and it improves its an air leak somewhere.
@@TitaniummanGarage thanks for pointing me in the right direction. My vent line off the gas tank was broken and all dry rotted and the air line with the inline filter that goes from the engine to the air box was really soft. I replaced both with new lines and it runs like new!
@@kippiemoore7439 Is it an H.O. Or Non H.O.? You have one Vacuum line on the carb and 2 ports on the airbox side of carb for the breathers. The vacuum goes to the fuel pump. If its non H.O It should be on the top left and reverse for H.O. If gas shoots out of the carb...it would be timing. You said breather. I would check your needle and seat and jet. something is plugging up loading your carb with fuel. I would check your fuel lines too and fuel filter. Even with a rebuild or cleaned carb, dirt can still come from tank or soft lines and plug something up. if it hasn't been done I'd replace the fuel lines too.
1:41 so the hose that goes from the breather hose coming from the bottom of the engine with the filter in line. then goings to the airbox should that hose be sucking air in or out because on the filter it says the air is going into the engine not out and I can feel the air coming out and hear it. you can even hear it when the lid is on and seat. im asking because i dont remember it doing that i dont know if thats normal or not thanks
Doesn't trust advice to clean the OEM carb to do a good enough job, so replaces it with minimum-price clone, because it comes with clean parts, even with the knowledge that it won't last very long. Also replaces fuel pump for good luck, I guess. Forgets to include the price of pump in calculations. Electrical-tape on the cracked intake pipe finally fixes (?) the problem. Doesn't want to buy an ultrasonic cleaner, because it costs about as much as a throw-away replacement carb. Is excited to share his "Quick fixes", that come after doing everything the most circuitous route, before attempting the exterior observations that lead to such quick fixes. I think I better buy a helmet before I end up all the way like this. (admittedly, I ran to the garage to check my flexible intake pipe for cracks and remembered I have a spare carb on hand)
If your talking about me. Those were quick fixes to narrow down what the issue is. I have a cheap sonic cleaner...It works like crap. Fuel pump is 15 bucks. I used the tape to temporarily fix the boot till I could order a new one. I have dozens of people having issues with cleaning their carb. So my suggestion is to buy a cheap one...see if that is the issue. For 37 bucks, it worth finding out if it's the carb causing all the headaches or fuel pump or something electrical. These are all suggestions so the average guy can troubleshoot their issues without dropping a ton of money.
@@TitaniummanGarage Yeah. It was pretty insightful. Like I said, I went to check for air leaks after watching. I think my problem is mostly old, dried-out fuel though, as it's starting to run better and with less smoke, on fresh stuff. On my ATV, I'm willing to make nearly any excuse to avoid the amount of disassembly required to swap in that other carb. :P
@@buckstarchaser2376 I hear ya. I hate working on carbs. I spent a good amount of time on a 700 carb. Cleaned it 3 times. Didnt work. I grabbed another oem carb and it ran great. Maybe try sea foam in the tank if its getting better. Helps clean the carb.
Hey friend This is Winnie from Kemimoto. Would you like to make a review video about the Carbon Belt for Polaris sportsman? l have emailed u the details, please feel free to contact me.
Carb kit will cost you 40 bucks ...so 38 for a whole carb is worth it ..............Bet that boot is expensive ,,,Scrap radiator hose off a car or truck will work in a pinch
I have a 99 Sportsman 500 two years ago and broke the cam and I had to replace it a local dealership and ever since then it only seems like I'm getting half of the power that I had before I could have the throttle wide open and it's still seems like I'm only about half throttle they didn't replace the Rockers they just replace the cam I guess since then this dealership has gone under because they had crap employees and crap owners and I don't think they did mine right before so I could just haul ass everywhere I'm going now not so much replaced it with that Polaris cam
Thanks X 100 for your posts. Bought an 1999 Polaris for my son and we've used a lot of your video's to fix it up. I was really baffled because we had changed cam, fuel pump, fuel lines and carb, but couldn't get rid of the bogging down and backfiring. My intake boot was cracked in the same location as yours...problem solved. Cam needed changed anyway...same probably goes for the carb and fuel pump.
Brother you helped me out just by saying check your diaphragm. My $38 dollar carb from Amazon was absolutely shit. I was driving down the rd and the little pice that’s on the diaphragm fell off and absolutely made it run like shit. Well I went back out after watching this vid and put my finger over the hole and it completely fixed my issue
Intake boots are a common source of air leaks. Not just on an ATV but on chainsaws , snowmobiles and motorcycles.
I use nonflammable brake cleaner to find air leaks.
Just start the engine and spray the area you suspect.
The instant that spray hits the leak the engine rpms will fall off. Works awesome without fire risk.
Also works great for finding crankcase leaks on 2 strokes..
Thanks for your videos!! I have a 2000 sportsman 500 that bogs and dies going up steep hills even when loading in my truck. Runs fine on flat ground.
Awesome 👌, just yesterday had to work on my Polaris sportsman 325 would not stay on...took out the spark plug was black and smell like gas... cleaned it out put back on problems solved but did noticed a back fire ...in reverse. I will look into carb hose and also my choke on it is acting up .
I have a question? I have a 1998 Polaris sportsman 500 4x4 I brought back from death. I used alot of your videos by the way great work. But now I have it runnning fine 3 or 4 times and then I kill it and when it goes to start again the crank bearly moves - but it runs fine when has a fully charged battery for a little while. it has a new stator and pulse coil and new head gasket and cam and rocker arms and checked valve to 0.06 and air gap is at 0.20 for pulse coil. Im stumped only thing I can think is maybe the voltage recticfier regulator is quirky. Just thought I would ask if you have time any advice would be appriciated. Thanks. from all the followers of his channel - He does good work and advice is never a bad thing.
Regulator rectifier will keep battery charged. I would check your ground wires. Maybe replace regulator. These 500 need a good battery. If you bought a cheap one they don't last long. Start there. Something is draining the battery. I'm glad you like my videos.
@@TitaniummanGarage Thanks just ordered a Voltage rectifier and CDi to be safe. Watched another video of yours on bogging Polaris and saw some good info on hoses and air leaks and carb to head tube so will check that out tomorrow thanks again for all the great videos and good advice its appriciated.
@@TitaniummanGarage I have a 2006 sportsman 500 HO efi that I bought. It doesn’t start. I checked and it has spark, fuel, and compression. I checked the valves and set them at .006. New spark plug too. Still no luck. Any ideas?
I’ve been trying to figure this out and it sounds like we have the exact same issues. Time to fix the things you mentioned and see how it does. Thank you for this video
Thanks for your help on my previous questions - it ended up being my sparkplug and sparkplug wire
With these 4 wheelers ..it could be anything. Glad you found it.
A little off the subject... I have a "2012" Sportsman HO 500, with believe it or not, less than 50 hrs on it. Back a few months ago I noticed around 5000 rpm it would bog down and almost die an get that pop pop pop on hills.. It idled and run fine otherwise. Since I hadn't rode the thing very much, I believed it was trash in the carb. I cleaned the carb and replaced the jets.. No improvement. So, I purchased and installed a new carb.. Problem didn't improve. I changed the plug.. No help. I replaced the pulse pump and all the fuel lines.. No help. Removed and cleaned the tank.. No help. I knew the air filter was new, so I hadn't even given it a thought it might be the problem. But, one evening while listening to the engine idle, and revving it a little.. I thought I'd remove the filter cover and see how it run.. and it actually improved a little.. So, I removed the filter, and it improved a little more. And that's when I found the culprit. All that money spent on parts, time of changing them out.. and the irritation of worrying about this bike.. came down to the hard plastic sleeve inside the rubber breather tube, that prevents the rubber from crushing when you tighten the air filter onto the rubber intake hose. When I replaced the air filter, I had invariantly caused that little hard piece of tubing to be turned sideways inside the rubber breather hose.. which allowed enough air for the bike to idle and run half throttle, then fall on it's face around 5K rpm or so. Moral of the story.. Check everything, even if you think it's correct.
I actually believe I did the same thing! Over tightened the clamp on the tube just outside air filter box and it left a big v shaped hole into intake. Ran way better once I loosened it.
I took a little all purpose glue.. the kind that stays flexible, and smeared it around the hard plastic sleeve.. Then slid it into place and let it dry overnight. Worked well!
I was actually thinking of doing the same thing to the intake manifold boot the carb connects too. Put a bit of Flex seal all around it. I don’t think it leaks cuz I tried starting fluid all over it while running and it Nvr reved up. But don’t think it could do anything to hurt it. Only possibly help. I gotta get Mr. Titanium to do a total carb and jet video. Guess that’s one night ce thing bout EFI.
Good videos. You sure know Polaris… quick question. I have a 2000 sportsman 500. Runs good idles good doesn’t loose power but when I let off the throttle sometimes it backfires and even shots flames from the exhaust manifold where it conects to the rest of the exhaust. Could it be my intake boot.? Or ?
Usually a backfire is running lean. Unless its loading up with gas. Might wanna check the boot.
As has been talked about before if the common issues checked dont fix the issue check the camshaft for a rounded off lobe on its central exhaust cam , its well known very common issue with this engine and causes bog and backfires as a symtom. , some CDI boxes will fail to maintain proper spark timing and cause backfiring and loss of power if the battery voltage regulator fails and the charging voltage goes to high at higher engine Rpm's.
Are these the same carbs they come with ?
I wanted to do an HO carb
Do you have videos of setting up the choke ?
Also where do you buy your fuel hose vacuum hose etc...
I have a scrambler 500 4X4 pretty much just ride it in the snow ...
I try and keep everything in good shape
I think I have to put a bendex in mine man she makes some noise if it doesn’t start right up I I’m hoping it doesn’t need a flywheel 🙏🏻🙏🏻🙏🏻
Thanks for the videos ...
I go to my local auto parts store for the fuel and vacuum lines. These carbs are identical. I have put a HO carb on. You need the carb boot too. I also put a HO cam in. The exhaust will get hotter so to do it right you might need to change exhaust.. I made a video on carbs and a video on a full build I did changing the carb to an HO with the cam. Polaris magnum 500 brought back to life was the title.
@@TitaniummanGarage thank you sir for the information I appreciate it ...
I have questions I hope you can help me. I have a 2001 Polaris 700 is not start I took it to a local shop charge me 1649.00 but still not working he told me he change the wire harness and I ordered a new cab and fuel pump but still not working
@@fajlustshegchannel7809 what is it doing? Does it turn over bit not fire? 700s are known for bad wiring. Did he replace the stator? Check for spark? I could go 5 different directions with this. I would need more info.
@@TitaniummanGarage Thank you for reply back to me I will have that check
I have a 1999 500 sports man and it’s like slow runs good no problems fastest I’ve got riding it was like maybe 40 any ideas?
Great video why this wasn't shown as first option for my search I can't imagine the exact year with the exact problem and this was at least the 10th time I searched the same exact thing over past couple of years and this is the first time it ever showed up from search anyhow first time I've saw the exact four wheeler get worked on thanks
I have a 2000 scrambler 500 and it is very hard to get stated and once it does start it won’t idle and runs rough won’t take a lot of throttle Boggs backfires at times and power comes and go’s but mostly only puts around. And dies then won’t start back.I’ve replaced the fuel pump took the carb apart cleaned it best I could. The starter button is kinda messed up too but works. Took the valve cover off and the exhaust lobe looks to be ok.I don’t have a lot of Polaris experience but built many many Hondas and Yamahas it wouldn’t run at all when I got it but I’m rather frustrated at this point. Not sure what route to take.
Hey. I have an 01 scrambler 500. Did you figure it out?
I have a 2008 Polaris sportsman 400 HO . It sat for years ,only has 30 hours on it and it's 13 Yeats old ! A Polaris dealer put a battery in and air filter for my friends widow. Charged her 500 bucks and gave it back ,it started but ran like scrap ! I found 2 clear plastic tubes up under gas tank plastic cover that were not connected to anything ! I blew in the hose and could hear gas bubbling in the tank? So I tried starting it and it ran better when I did that. Soon as I stopped engine would bog!I put a bunch of Sea Foam in gas and it started running better ! Every tank running better ! Out of nowhere it all just start dying out unless you put choke on to keep it running! Sometimes runs with no issues at all and then it will start bogging dying out.It can run for hours without issues ? I also found the thick tube coming from engine to air box had that plastic filter thing melted from hitting the exhaust at one time! I saw you talking about the vent lines to the air box being important and wondered if that could be the issue. Also can't figure where the two smaller clear plastic tubes on top of tank are supposed to connect . They just lay up there open ended.
The tubes on top are the tank vent hoses. If they are blocked it will cause gas not to flow. So you did the right thing blowing in them to see if they are clear. That plastic filter that is melted would most likely be your problem. Not sure why its on the exhaust side. The vacuum hose from air box on exhaust side goes to top of the oil reservoir. The tube from the engine with the filter goes up the PTO side of the engine into the air box. If its plugged/melted it will cause your condition you described. I would clean the carb as well. The jets might be dirty from sitting. Seafoam is your best friend but won't unplug jets.
Seafoam is a miracle in a can. Wether for automobiles or atv’s it’s magic! Especially with old gas or storage of gas for long.
I have the same issue, gonna check the carb boot on my polaris 500
I have the same problem what should i replace first or check first
My Sportsman 400 is having issues like this it only runs good when the air cleaner is off I went through the carburetor and cleaned it up nothing was really in the carb so maybe when I get home tonight I'll look at the intake
instaBlaster
Mine was because of old fuel. I siphoned everything from the tank and put some seafoam ( A little more than recommended lol) then filled it with new fuel. I had to rev it for probably 10 minutes all together until the new fuel finally cycled through and cleaned everything.
just acquired a 97 Sportman 500 with this issue. are you taking in units for repair? I am also in WI
I have a 1995 Magnum 425 that runs great other than… from a dead stop it will rev out just fine, but after about 2 seconds (with the engine still under load and over 1/2 throttle) it will bog down. There’s obviously enough gas off idle, but I c ant figure out why it wants to bog under load. Override switch makes no difference. Carb is perfectly cleaned and needle clip is set in the middle. Carb boot is brand new. And fuel pump is brand new. Maybe it’s a vacuum leak from the carb to fuel pump? I’m out of ideas.
Did you ever get to fix it?
@@fealiks no. Sold the quad a few months later.
@@jeepsandfarming ok yeah, I think I’m going to sell it too, i had just fixed a big exhaust leak a couple days ago and first drive today and it broke again. This model feels like it’s cursed or something. We’ve put over 2k$ in it in the past year and we never even got one full drive in before it broke down
So Jedi master of Polaris wheelers. I watched your “bogging video” I bought one of the cheap Amazon carbs and checked the intake for leaks with starting fluid. Got new air filter and replaced plug and fuel line. Got a fuel pump with carb but didn’t put it on yet. Anyway the main jet on the Mikuni carb was a 142.5(0-3000’ elevation) but it’s it’s generally ran pretty well at 6k’ (my house sits at 6280’) anyway the new temporary carb (while I rebuild and clean up mikuni) came with a 145 and 180 main jet. I put in 145 but in Haynes/cylmer says at higher than 3000’ I should be using a smaller main jet. So I ordered a 30 pack of jets and needles and all that. It runs great with the 145 in till I get passed half throttle then it falls on its face. So should I put in a 142 or 140? If you could do a video on proper jetting procedures(like I said I got 10 main jets a bunch of longer, different ones that I’m not sure what to do with plus 2 other different styles). Id be more than willing to pay you thru Patreon or even Venmo! I’m just at my wits end! It’s a 96 I got for helping sister move. But I have an opportunity to buy a 2002 HO WITH THE EBS, for very cheap but it’s sat 4 yrs+. So I know I’m going g to have to go thru all this carb cleaning and such stuff with it as well. But I don’t want to buy it u til I got the 96 to where I can at least trust it to go off road(on road only now in case I gotta go tow it home, since I live up in the hills. Thank you for sharing your excellent knowledge with us less talented DIY’ers! Plz consider jetting/jets video! You humble fan always! 🙏
Love the comment! Thanks. Hmm... smaller jet? With the vaccum operated carb and higher elevation I would have thought a bigger jet. Let me research that one.
Thank you so much. Now I hope it’s smaller tho cuz I just went from the 142.5(mikuni) to a 145(Amazon) to a 135(but can easily switch to 140 since I haven’t put anything back together yet.
Minimprover 30PCS Carburetor Accessories Kit,10 Pcs Slow Pilot Jets and 20PCS Carburetor Main Jets for PWK Keihin OKO CVK KOSO PE PWM
Minimprover 30PCS Carburetor Accessories Kit,10 Pcs Slow Pilot Jets and 20PCS Carburetor Main Jets for PWK Keihin OKO CVK KOSO PE PWM
This is the kit. All I was after was the “main jets.” This is why I wish a smarter man like you would do a video on these carbs, mikuni sand Amazon/Ebay Chinese models. Right in line with main jet I thought the long skinny jets may go. I got a screwdriver just to check it out n the brass sides stripped without jet even budging. I’m talking the Lil one inside the bowl, not the 1n 1/2 turn out one, that is outside the bowl(1 n1/2 turn out from tight on 96-97, and 2 n 5/8 turns out from tight on 98+(according to my Cylmer maintenance book). So plz help. Thanks Yoda!🤣😎👍🙏
Damn my last post was supposed to be a link to Amazon! I guess I need more help than just carb jetting! You do iphone tech classes too? Hahaha
Yeah your problem is chinese carb.
If you could take the old one off the replace it. You can clean the old one you goober.
I have a 1999 Kawasaki prairie and I have to give a lot of throttle to get it to start going.I think somethings wrong with the clutch but I don’t know
I need some advice I just bought a second 96 sportsman 500 and it smokes a lot and has almost not power if you hit the gas but idles fine I’m sure it needs a new piston but the rocker arms have some side to side play do you think it will need rockers and a cam or is it possible that oil is leaking into the cylinder from the valves causing the problem
Black or white smoke? Black would be oil ring or valve seals. white would be blown head gasket. There will be a little side play. I guess it depends on how wore the rockers look and check cam lobe height to see if its in mechanical limits.
I just replaced the exhaust donut on the pipe and it already burnt it up. This is a 1999 polaris sportsman 500. Should I just put another donut and put extra springs on to keep it from moving?
It burnt up? Sounds like your running it to hot. Do you have the stock carb on it? But yes spring would help with the wear.
@@TitaniummanGarage it is the original mikuni carb and I so think it's running just a little bit lean because it backfires when you let off the gas after revving. But I found out the donut springs are stretched after 22 years so I'm going to get some new ones and a new donut
Check the carb boot. If it's that old I would replace it. That would cause a backfire or lean condition.
Hey man, this is the channel I've been looking for ! I've got a 05 500 EFI that runs ok for a while then bogs down and dies. I checked the plug and air filter. Ran some BG and heat and changed the fuel filter. got better but still dies. I finely put a new plug the other day and I know, should have done that first, and it ran like new... for about 2 hours, then did it again. any ideas ?
I would try a cooler spark plug first. If that doesn't help it could be an issue with the fuel pump or wiring. Check for soft wires that may have heated up from riding.
Hey just so I understand as well…. With NGK plugs the higher number the cooler the plug correct?
I have a 2016 polaris sportsman 570 spins over and backfires through airbox but when it starts it won't idle until it warms up then it runs and starts fine
What size wrench did you cut down?
12 mm
hi I have a 96 polaris explore 400 starts up and idles, but when u hit the throttle it dies , didnt check the throttle cable yet or fuel pump. any other idea's ????
I have 1994 Polaris 2x4 300 2 stroke, I’ve cleaned the carburetor so far, but it start up fine and runs about 200 yards and then bogs down and shuts off. I give it like 30 seconds and does it over and over again. What do you think I should replace to start off with ?
Those are gravity feed for fuel. Loosen you gas cap and see if it still does it. I've also seen the fuel shut off get clogged.
Please show how to bypass the reverse limiter.
I actually never did it on a 500. Never needed to. Sorry.
@@TitaniummanGarage I have a Sportsman 335.
Neutral switch.
Is there an adjustment for the choke valve
My prob is gas come out of carb intake small hole
I have 2 2005 sportsman 400s and they both bog down and sometimes back fires when giving full throttle. When you go 1/4 to 1/2 throttle they seen to be fine just going from 1/2 to full throttle they bog down and don't wanna make any power. What should I check
It sounds like you need a carb clean..do you use fuel with ethanol in it? Its horrible for the carbs. Gums them up. The next I would check is the timing and if the cams are worn out.
Great video finally someone who knows what’s going on thanks
Mines actually bogging out in reverse just gnarly running in reverse when ya go. You have to give it a ton of throttle to get a hill pulled.
Your pushing and holding the override button right? If so it's your rev limiter.
What kind of air box hoses should it be
Any rubber hose. I think its 5/8ths.
Olá.
Sabes se o cilindro da polaris scranb 400 da na sport 400.
Obrigado
I gotta problem with my 07 Hawkeye 300
How can I get in contact with you
I haven't worked on any Hawkeye's I try and stick to 500s and 700s
Can anyone help me with my 2001 425 expedition. The transmission is locked up the rest of the atv is in great shape it be great if someone has tackled this and has some advise. Thanks
My time is worth my money, thats why i rebuild the oem whenever possible, otherwise youre paying $40 per year per machine, plus you have to take off the front plastic and gas tank on these to get to the carb. If that doesnt work then ill go cheap ebay carb.
I have an 01 sportsman 500HO, mine does bog down but only sometimes, doesn't matter what position throttle is in, it will eventually go away on its own, any suggestions?
Could be a couple things. Check the carb and boot. I would also try the cdi. Maybe try unplugging the black wire. I had a 2000 that the cdi would sometimes work and sometimes not. If the black wire trick works then you know it's the cdi. But I would check the diagram on the carb and clean the carb first.
Thanks Bro for a lot
I have a question. I have a 2004.5 sportsman 400. It has an issue where it bogs down and loses power only in high range, low and reverse are fine. It does it only going up a hill under hard acceleration. I can drive on flat ground at full speed no problem. But when under a load if you give it full throttle from a dead stop it bogs hard and you have to let off and then it comes out of it. I have replaced spark plug, plug wire, coil, cdi, stator, rebuilt carb, new air filter, new buttons on secondary clutch, new belt. Still no luck. Any ideas would be greatly appreciated. Thank you!
Check your air lines to make sure nothing is pinched or leaking. See if the one way valve on air line is not clogged. also check to see if your fuel lines are soft. If so they can collapse under vacuum. Another thing is to check to see if your running rich on the carb. If you take the airbox cover off and it improves its an air leak somewhere.
@@TitaniummanGarage I’ll give that a shot thanks for the reply 👍🏼
@@TitaniummanGarage thanks for pointing me in the right direction. My vent line off the gas tank was broken and all dry rotted and the air line with the inline filter that goes from the engine to the air box was really soft. I replaced both with new lines and it runs like new!
Right on! Glad I could help.
My Polaris 500 is backfiring through the backfiring back through the breather
What could be causing that?
Timing is off. Check your valve lash and timing.
It wasn't popping and spitting until the vacuum lines came loose so it's not the timing.
How many vacuum hose lines are there on my Polaris sportsman 500
Where does the vacuum line go to that comes off of the bottom of the carburetor?
@@kippiemoore7439 Is it an H.O. Or Non H.O.?
You have one Vacuum line on the carb and 2 ports on the airbox side of carb for the breathers. The vacuum goes to the fuel pump. If its non H.O It should be on the top left and reverse for H.O. If gas shoots out of the carb...it would be timing. You said breather. I would check your needle and seat and jet. something is plugging up loading your carb with fuel. I would check your fuel lines too and fuel filter. Even with a rebuild or cleaned carb, dirt can still come from tank or soft lines and plug something up. if it hasn't been done I'd replace the fuel lines too.
my friends fourwheeler bogs when you get on the throttle too much and you cant open it all the way up without it bogging at 3 quarters throttle
That's the same problem I'm having, I haven't figured it out yet.
I have rhisnissue too. I think its the coil or cdi box
1:41 so the hose that goes from the breather hose coming from the bottom of the engine with the filter in line. then goings to the airbox should that hose be sucking air in or out because on the filter it says the air is going into the engine not out and I can feel the air coming out and hear it. you can even hear it when the lid is on and seat. im asking because i dont remember it doing that i dont know if thats normal or not thanks
I believe it goes out into the airbox.
@@TitaniummanGarage okay thanks I thought it was a problem
My 2008 500 ho bogs down when trying to go full throttle and I can't seem to figure it out
Clean the carb, Check for any issues with the carb boot and hoses.I'd check the timing as well and your valve lash.
That 37$ is far better than 500$ and even if the 37$ one is junk you still have new parts for the old carb !
Many things... One thing that wasn't mentioned... Spark arrestor.
Doesn't trust advice to clean the OEM carb to do a good enough job, so replaces it with minimum-price clone, because it comes with clean parts, even with the knowledge that it won't last very long. Also replaces fuel pump for good luck, I guess. Forgets to include the price of pump in calculations. Electrical-tape on the cracked intake pipe finally fixes (?) the problem. Doesn't want to buy an ultrasonic cleaner, because it costs about as much as a throw-away replacement carb. Is excited to share his "Quick fixes", that come after doing everything the most circuitous route, before attempting the exterior observations that lead to such quick fixes.
I think I better buy a helmet before I end up all the way like this. (admittedly, I ran to the garage to check my flexible intake pipe for cracks and remembered I have a spare carb on hand)
If your talking about me. Those were quick fixes to narrow down what the issue is. I have a cheap sonic cleaner...It works like crap. Fuel pump is 15 bucks. I used the tape to temporarily fix the boot till I could order a new one. I have dozens of people having issues with cleaning their carb. So my suggestion is to buy a cheap one...see if that is the issue. For 37 bucks, it worth finding out if it's the carb causing all the headaches or fuel pump or something electrical. These are all suggestions so the average guy can troubleshoot their issues without dropping a ton of money.
@@TitaniummanGarage Yeah. It was pretty insightful. Like I said, I went to check for air leaks after watching. I think my problem is mostly old, dried-out fuel though, as it's starting to run better and with less smoke, on fresh stuff. On my ATV, I'm willing to make nearly any excuse to avoid the amount of disassembly required to swap in that other carb. :P
@@buckstarchaser2376 I hear ya. I hate working on carbs. I spent a good amount of time on a 700 carb. Cleaned it 3 times. Didnt work. I grabbed another oem carb and it ran great. Maybe try sea foam in the tank if its getting better. Helps clean the carb.
Whys my trailboss 330 making a shhhhhhh sound and not starting with electric start or even pull start
Hey friend
This is Winnie from Kemimoto. Would you like to make a review video about the Carbon Belt for Polaris sportsman?
l have emailed u the details, please feel free to contact me.
I'm not sure how you would have my email?
@@TitaniummanGarage If you are interested in it, you can email me-mktg03@syzbranding.com
Carb kit will cost you 40 bucks ...so 38 for a whole carb is worth it ..............Bet that boot is expensive ,,,Scrap radiator hose off a car or truck will work in a pinch
I have a 99 Sportsman 500 two years ago and broke the cam and I had to replace it a local dealership and ever since then it only seems like I'm getting half of the power that I had before I could have the throttle wide open and it's still seems like I'm only about half throttle they didn't replace the Rockers they just replace the cam I guess since then this dealership has gone under because they had crap employees and crap owners and I don't think they did mine right before so I could just haul ass everywhere I'm going now not so much replaced it with that Polaris cam