HELP!! 2007 Sportsman 500 HO EFI Smoking - Engine Rebuild or Used Engine?

[pglover19]

I purchased my first ATV on Friday. I am new to ATV riding and wanted to purchase a Polaris Sportsman 500 HO to learn how to ride. My goal was to purchase something cheap. So, I found and purchased a used 2007 Sportsman 500 HO EFI ATV. The ATV has 1977 miles and 313 hours on it. I brought it for a great price (less than $2K), but after taking the panels off today and doing a thorough investigation of the ATV, it looks like there may be engine and other problems. I can tell that the owner did not do the maintenance required. I changed the oil, oil filter, and spark plug today. The oil was really dirty. Below are some of the problems I find. However; what concerns me the most is the blue smoke on startup and when driving the ATV. Not alot of smoke, but there is smoke. I pretty sure the smoke is blue and not black. It smells like oil burning and I am afraid, I need to rebuild or buy a used engine. A friend of my do a valve compression test and it was 60 PSI. Please advise on things to check to determine if I need to rebuild or replace the engine. Additionally, do you think I made a good purchase even with all the problems listed below...

Problems Discovered:
- Blue smoke from Tailpipe
- Exhaust Manifold Gasket leaking
- Leak in Radiator
- CV Boot on Rear Leaking
- Oil Reservoir Vent Hose Cracked
- Back Brakes not working

[ATVDOC]

Sounds like you got a good deal. Black smoke is an indication of the fuel system running too rich. What you want to worry about is blue smoke. That means rings, valve guide seals, etc. The burning oil smell is likely a valve cover gasket leaking and/or missing screws dripping oil onto your exhaust manifold. Compression testing is not accurate on the Fuji 500 because of the compression release on the camshaft. The 500 is a notoriously rugged engine, so I'll bet there's a bunch of life left in it. Overhaul your carb(jet needle, needle jet, float needle/seat & o-ring, float pin, float bowl o-ring, pilot screw o-ring). Clean it well, & it should run great. I think you got a great deal on one of the best versions of the Sportsman Polaris ever built.

[pglover19]

Originally Posted by ATVDOC

Sounds like you got a good deal. Black smoke is an indication of the fuel system running too rich. What you want to worry about is blue smoke. That means rings, valve guide seals, etc. The burning oil smell is likely a valve cover gasket leaking and/or missing screws dripping oil onto your exhaust manifold. Compression testing is not accurate on the Fuji 500 because of the compression release on the camshaft. The 500 is a notoriously rugged engine, so I'll bet there's a bunch of life left in it. Overhaul your carb(jet needle, needle jet, float needle/seat & o-ring, float pin, float bowl o-ring, pilot screw o-ring). Clean it well, & it should run great. I think you got a great deal on one of the best versions of the Sportsman Polaris ever built.

I have corrected my post.. I am pretty sure it is blue smoke and not black smoke..... Sorry for the confusion.. So, what causes blue or black smoke and what do I need to do to correct the problem? Once again, I am a novice but I am trying to learn as much as possible about this ATV and will be doing most of work with the help of my neighbors who has ATVs already...

[pglover19]

Originally Posted by ATVDOC

Sounds like you got a good deal. Black smoke is an indication of the fuel system running too rich. What you want to worry about is blue smoke. That means rings, valve guide seals, etc. The burning oil smell is likely a valve cover gasket leaking and/or missing screws dripping oil onto your exhaust manifold. Compression testing is not accurate on the Fuji 500 because of the compression release on the camshaft. The 500 is a notoriously rugged engine, so I'll bet there's a bunch of life left in it. Overhaul your carb(jet needle, needle jet, float needle/seat & o-ring, float pin, float bowl o-ring, pilot screw o-ring). Clean it well, & it should run great. I think you got a great deal on one of the best versions of the Sportsman Polaris ever built.

This unit is fuel injected (EFI) and does not have a carburator....

[pglover19]

Originally Posted by ATVDOC

Sounds like you got a good deal. Black smoke is an indication of the fuel system running too rich. What you want to worry about is blue smoke. That means rings, valve guide seals, etc. The burning oil smell is likely a valve cover gasket leaking and/or missing screws dripping oil onto your exhaust manifold. Compression testing is not accurate on the Fuji 500 because of the compression release on the camshaft. The 500 is a notoriously rugged engine, so I'll bet there's a bunch of life left in it. Overhaul your carb(jet needle, needle jet, float needle/seat & o-ring, float pin, float bowl o-ring, pilot screw o-ring). Clean it well, & it should run great. I think you got a great deal on one of the best versions of the Sportsman Polaris ever built.

Ok.. I have confirmed that the smoke is blue to white in color. One other thing to add is that there was no air filter. No sure how long the owner was running the ATV without an air filter, but I installed one today.. Could that be the cause of the engine smoke.....

[ATVDOC]

Originally Posted by pglover19

This unit is fuel injected (EFI) and does not have a carburator....

Hey, my bad, still running rich for some reason. I guess you've replaced the air filter, verified no obstructions in the snorkel, & no check engine message showing. Check to make sure you idle is 1150-1300 rpm. If not, check your wiring at the connectors of your sensors for breakage. To do this, GENTLY pull on the wires where they enter the connector. If they're broken, you'll see the insulation turn white & stretch. If don't see any problems, then check to see that your fuel pressure isn't too high(39-40 psi). Also know that Polaris programs into the ECM an after-start fuel enrichment period. You will have some black smoke for a minute or so after start-up.

[pglover19]

Originally Posted by ATVDOC

Hey, my bad, still running rich for some reason. I guess you've replaced the air filter, verified no obstructions in the snorkel, & no check engine message showing. Check to make sure you idle is 1150-1300 rpm. If not, check your wiring at the connectors of your sensors for breakage. To do this, GENTLY pull on the wires where they enter the connector. If they're broken, you'll see the insulation turn white & stretch. If don't see any problems, then check to see that your fuel pressure isn't too high(39-40 psi). Also know that Polaris programs into the ECM an after-start fuel enrichment period. You will have some black smoke for a minute or so after start-up.

My friend helping me today confirmed that the smoke is blue/white in color.. Look at my previous post about not having an air filter.

[ATVDOC]

Originally Posted by pglover19

Ok.. I have confirmed that the smoke is blue to white in color. One other thing to add is that there was no air filter. No sure how long the owner was running the ATV without an air filter, but I installed one today.. Could that be the cause of the engine smoke.....

Whoa, I'm still figuring out my posting. I just answered your message that you are EFI. Sorry. Yep, running without an air filter probably has "dusted" your rings & bore. This is where you decide on a top-end job(piston, rings, valves, seat re-face, gaskets, o-rings, & bore job), or e-bay. Do the job yourself, about $500. Take it to a dealer, around $1250 or so. The difference is labor & use of factory parts. A used 500 on e-bay last time I checked was 500-750 bucks.

[Russ C]

I would change oil, make sure its full and ride it awhile, see if its using oil, check it every ride, if its using alot , then think about the over haul, no air filter probably didnt do itany good but try it awhile and see

[pglover19]

Originally Posted by ATVDOC

Whoa, I'm still figuring out my posting. I just answered your message that you are EFI. Sorry. Yep, running without an air filter probably has "dusted" your rings & bore. This is where you decide on a top-end job(piston, rings, valves, seat re-face, gaskets, o-rings, & bore job), or e-bay. Do the job yourself, about $500. Take it to a dealer, around $1250 or so. The difference is labor & use of factory parts. A used 500 on e-bay last time I checked was 500-750 bucks.

I rather do a rebuild versus buying an engine from Ebay.. However; I am clueless in doing it myself. My friends has done rebuilds in cars, but not ATVs. Can you provide me some guidance on how to do the rebuild. Are you located in VA or know someone in Richmond, VA that could help me... Once again, I would love to do this myself, but I have no mechanical experience.