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Old 12-22-2012, 01:59 PM   #1 (permalink)
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Troubleshooting xc 500

Took my sled out yesterday. seemed to run fine other than a little low on power a couple times. I shut it off for a bit and then it took for ever to get started again, usually takes 1 pull when its warm. I was thinking it just needed new spark plugs at the time.

Today I went out to start it and the first pull seemed like it was locked up. then a couple more pulls seemed really different than normal, maybe unsmooth is the word i'm looking for.

Then gas started pouring out the exhaust pipe. I let it sit awhile and then pulled a couple more times and it seemed normal and almost fired up, but then it was back to "unsmooth" and the engine seemed like it was shook really hard, and more gas poured out.

I can turn the primary clutch by hand, but it doesn't pull over that easy.


Did I blow it up or ? It does have about 5500 miles
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Old 12-22-2012, 02:04 PM   #2 (permalink)
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Either it's hydro locked with gas or it's blown up. Pull plugs and drain the cases and turn gas off and pull over slowly to get gas out than do. Compression test.


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Old 12-22-2012, 02:43 PM   #3 (permalink)
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I'm with Polaris650. Probable causes would be an inlet needle/seat that is letting gas by and filling up the case, or a ruptured diaphragm in the fuel pump that is letting fuel into the case via impulse line. Definitely drain before starting, as this gas has no oil in it for lubrication. It wouldn't hurt to put a bit of oil down the plug holes just for grins...

That's the main reason it's suggested to shut the gas off when not using the sled.
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Old 12-22-2012, 02:48 PM   #4 (permalink)
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I'm with Polaris650. Probable causes would be an inlet needle/seat that is letting gas by and filling up the case, or a ruptured diaphragm in the fuel pump that is letting fuel into the case via impulse line. Definitely drain before starting, as this gas has no oil in it for lubrication. It wouldn't hurt to put a bit of oil down the plug holes just for grins...

That's the main reason it's suggested to shut the gas off when not using the sled.
Alot of people, rather than using starting fluid or straight gas, will make a bottle of premix in a spray bottle for lubrication.
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Old 12-22-2012, 03:38 PM   #5 (permalink)
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I shut the gas off after I seen it pouring out.

Whats the best way to drain the gas? So after I drain it, I should put a little oil straight in and try to start it?

I want to be very sure of what I'm doing, I can't afford to cause any damage because my own ignorance.
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Old 12-22-2012, 04:30 PM   #6 (permalink)
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I shut the gas off after I seen it pouring out.

Whats the best way to drain the gas? So after I drain it, I should put a little oil straight in and try to start it?

I want to be very sure of what I'm doing, I can't afford to cause any damage because my own ignorance.
Pull the lines off the carbs and take the bowls off. If you can take the bowl directly down and dump it it will save a mess. Make some 40:1 premix instead of using straight gas. If all of the gas is bad disconect it before the shutoff and put the hose in a bottle and let it flow in with the gas lid off.
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Old 12-22-2012, 04:34 PM   #7 (permalink)
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Now I'm confused?

I thought I was to drain the gas out of the engine. The gas in the sled is fresh, I just bought it yesterday.
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Old 12-22-2012, 04:59 PM   #8 (permalink)
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Just drain the gas out of the motor. There are 2 10mm I think bolts under the y pipe on the bottom of cases. Pull those out. Make sure gas is off. Let whatever is in there drain out and than start to pull it over a few times(do not try and start it, just pull it over so the gas vapor will blow out) Than like bc Dan said pour a little oil down the cylinders for lube. No need to pull the carb bowls off.


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Old 12-22-2012, 05:04 PM   #9 (permalink)
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Should I leave the spark plugs in when I do that?
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Old 12-22-2012, 05:06 PM   #10 (permalink)
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No pull those out also.


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Old 12-22-2012, 05:11 PM   #11 (permalink)
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Thank you!
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Old 12-22-2012, 08:09 PM   #12 (permalink)
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Just drain the gas out of the motor. There are 2 10mm I think bolts under the y pipe on the bottom of cases. Pull those out. Make sure gas is off. Let whatever is in there drain out and than start to pull it over a few times(do not try and start it, just pull it over so the gas vapor will blow out) Than like bc Dan said pour a little oil down the cylinders for lube. No need to pull the carb bowls off.


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x2. Didnt read whole thread like i should of. I thought he had bad gas in the carb bowls from sitting. Do what they said pull plugs and then bolts, put a few drops of oil in each cyl. And pull a few times.
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Old 12-23-2012, 12:28 PM   #13 (permalink)
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Do you have a diagram to show where the drain plugs are? I can't find them.

is it #5 on this? http://www.polarispartshouse.com/oem...c187/crankcase
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Old 12-23-2012, 12:54 PM   #14 (permalink)
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That should be them... They're directly under each cylinder.
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Old 12-23-2012, 01:58 PM   #15 (permalink)
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How far down is it, just by looking im not seeing anything between the y-pipe and the coolant hose.
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Old 12-23-2012, 02:05 PM   #16 (permalink)
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The plugs drain the crankcase, so are level with the bottom of the crankcase.
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Old 12-23-2012, 03:07 PM   #17 (permalink)
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Still lost, the only bolts I see are the ones holding the plate that the coolant hose is connected to.. I must be missing something but I've looked and looked.
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Old 12-23-2012, 04:50 PM   #18 (permalink)
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Look all the way at the bottom of the crank case, directly underneath each spark plug. As Dan said - they will need to be at the bottom of the case in order to allow for a complete drainage of the case.
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Old 12-23-2012, 05:23 PM   #19 (permalink)
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I should be able to see them with out taking anything off right?
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Old 12-23-2012, 05:29 PM   #20 (permalink)
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The one on the mag side is definitely visible. Look behind / under the coolant hose on that side and you'll see a smaller bolt head facing forward on the bottom of the case. The one on the other side will be in the same relative location and will be of the same size.
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