I managed to fix switch by taking apart and going through little springs/copper connectors/ball bearings/and cleaned then added dielectric….works fine…..starter wont roll engine when gets on compression stroke – I can barely pull with both hands to roll it past then it starts fine – I put a car battery on it and it still wouldn’t roll it over just made the cables hotter!!!
so I read this forum/google – seems these 500s have issues with compression release system on cam and wearing out exhaust cam lobes – sure enough I tore it apart and well…….for starters mine has a chip of the shinny plating on exhaust rocker where the little ball bearing gadget runs that does the compression release ( I believe ) so I know I am going to need an exhaust rocker at the least.
Next my dilemma,
1) is there a way to test the ball bearing thing in the cam to make sure it works before I reassemble. The exhaust lobe doesn’t look worn/bad but at this point and all the stuff strung all over my barn, im a little apprehensive about going back together w/out good stuff inside not to mention ruining a good gasket set because of old parts.
2) any recommendations for replacement cam/rocker combos brands? I see several on ebay but I don’t want to buy some junk only to have another failure. I didn’t buy this with anticipation of having to tear the engine apart.
3) should I hone the cylinder and rering the piston? I have no clue on the hours/miles on the unit, I would say it looks average for a 15y/o machine. Nothing great but not trashed.
4) Did I mention I have this thing in a bunch of pieces all over my barn and no proper tools or knowledge to put it back together such as timing it, torqueing things down to spec, no torque wrench, etc…….is there anyone in the KC area that might be willing to allow me to pay them for some repairs once I get parts and get ready to go back together with it?
My mom and dad own two Kawasaki bayous and a mule……..they have ALL been fool proof, no engine probs and one is 10 years older than this Polaris…..are they a lesser machine? I got this Polaris because of a recommendation of a friend and the fact it was a reasonable deal and 4×4 which my parents bayous are not. I am kinda wishin I hadn’t but hopefully after engine work it wont need so much.
Thanks in advance regarding help/recommendations – I look forward to your responses so I can figure out what to do. I am totally overwhelmed.
