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08-05-2010, 02:53 PM
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Junior Member
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Member #6342
Join Date: Aug 2010
Posts: 2
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Polaris Predator 500 (No Start)
Just acquired a 2004 Polaris Predator 500. Unit ran great and popped off everytime, however it leaked oil between the crankcase halves.
Tore the machine apart and resealed the case halves. Repalced all gaskets and seals. I followed the service manual to a "T" with regards to torque, timing, valve lash, carb cleaning, etc. I replaced the spark plug, checked compression (120 lbs.), I am getting fuel to the carb and all the lines are free of obstruction. The fuel filters on the petcock are both clean. I tried fresh gas. The choke cable is operational as well as the throttle mechanism. I even did a load test on the battery figuring maybe the plug would spark when there was no load on the battery but not when the engine was building compression. It tested fine. It sits at 12.6 V to start and only drops to 11.7 while cranking. I checked all the wiring and the pulse coil along with the stator and reverse coil. The only thing I have not tried yet is a leak down test.
The thing just will not start anymore. It cranks and cranks and cranks with an ocassional teaser of a pop through the exhaust (gets the hopes up). I don't get it. Very confused. What am I missing?????
I have worked on stuff like this for several years now and have never experienced this yet.
Rule of thumb: Fuel,Spark,and Compression = Running Engine.
Last edited by sidejob; 08-05-2010 at 03:15 PM.
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08-05-2010, 04:33 PM
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Junior Member
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Member #6007
Join Date: Jul 2010
Location: USA,kentucky
Posts: 22
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uhm, is the coil (that goes to spark plug) on the bike good? or uhm it could be somethin in the electrical sounds like to me the occasional pop is gas build up from not fireing up (its normal). i would take it to a dealer.......im not a pro about it lol
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08-05-2010, 04:37 PM
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Junior Member
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Member #6007
Join Date: Jul 2010
Location: USA,kentucky
Posts: 22
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i would try maybe pull starting it the old way by pushin it down a hill or somethin and pop the clutch.
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08-16-2010, 09:23 PM
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Junior Member
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Member #6583
Join Date: Aug 2010
Posts: 4
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had similar problem. do leak down and double check all your timing. cams might be just off alittle bit. my valves were smashed from being out of time.
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08-17-2010, 06:51 PM
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Junior Member
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Member #6342
Join Date: Aug 2010
Posts: 2
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Figured out!!!
Sheared Flywheel Key! FIxed and back up and going! 
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01-19-2011, 04:37 PM
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Junior Member
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Member #9888
Join Date: Dec 2010
Location: South Daytona, FL
Posts: 26
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what was it? just curious
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01-19-2011, 07:18 PM
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Polaris ATV Junkie!
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Member #8052
Join Date: Oct 2010
Location: me
Posts: 1,104
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Quote:
Originally Posted by bvisailer
what was it? just curious
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um he answer in the post above yours. a sheared flywheel key.
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