1998 Yamaha G16 + Polaris Scrambler 500 project

[stuff4mason]

Well, I got the engine mounted up this weekend. Instead of re-inventing the wheel, I used what I had. Built a bracket for the front (adjustable forward/backward) and for now, hard mounted the rear brackets. Clutches appear to be lined up well and belt has a little tension on it. Motor feels solid. I think my main goal at this point is to make sure this engine and starter are good before I spend a ton of time making it sweet. Next chore: how and where to hook up oil reservoir.

[smallblock450sl]

What, no pictures!

[stuff4mason]

Not yet smallblock!! Its mounted well enough to get it running, but probably not enough to fly down the road just yet. I want to hear this kitty purrrr before I put a ton of time into it. I'm going to work on getting the oil reservoir mounted, run new oil lines, and start looking at all this freaking wiring. The starter/pull cord cover was missing when I got it. So, I have a new/used one which should arrive tomorrow. Need to buy all of the bolts to the cover and the pump housing in front of it, as all of those bolts are gone. Then I can test the starter at least.

[stuff4mason]

I had a productive night last night! My starter/pull start cover arrived yesterday and it fit perfectly! I also tested the starter and after hitting it twice with juice, she came alive!! That's a very good step in the right direction!! I am still scratching my head as to why this cover wasn't there when I got the motor. There was mud in each bolt hole for the cover, which means they must have been running this motor without it. Confused...

These are the temporary mounts I built. The front isn't finished, as I am going to add more metal to the bracket to stiffen, but should work fine. I'll probably add another bar to the top right side mount later on from the engine cradle up.

I have a question: There is an "air breather" tube coming out of the top of the oil reservoir (third picture). It wasn't hooked to anything when I got the engine, and the parts schematics don't show where this goes. There is a spread clip on the end of the hose, so it must attach to something? External oil pump??? There is another barb fitting coming out of the front (top) of the engine (fourth picture). This one also had a hose attached to it (fifth picture) Where do these two go?

[smallblock450sl]

Great news about the "fire up" Sorry, can't help with the hose/vent question. Keep up the good work!

[mcdave71]

doesn't that vent hose just go to the breather housing?

[stuff4mason]

Yep, I think you are right mcdave. Now that you said that, I looked at the airbox parts diagram and it appears that both of those lines run to it. Thank you bud!!

[smallblock450sl]

Looked up parts diagrams for several year Polaris 500 Scramblers, seems yours is around a 2000 model and I agree with mcDave71, they seem to go into the airbox assy. Have I said this is going to be a killer trail car yet

[stuff4mason]

Yep! Dave your almost right on yet again!! Its a 2001 Polaris SCRAMBLER 500 2X4 (A01BA50AA). I got a couple of brackets constructed last night for the oil cooler. Should get it mounted and hooked up by the weekend. After three sets of screws and three trips to the store, I finally found the right ones. I made gaskets from a rubber-cellulose sheet for the water pump and starter cover and got them mounted. I test fit the exhaust and looks like the end of the pipe will require modification to drop below the bag well. I also test fit the radiator and fan. Looks like this will require to cut out the horizontal support bracket for the cowl. Guess it will have to be supported some other way....

I know Dave!! I am so stoked! I still to this day can't believe I picked up this project for $225.00!!! So far, I am only $420 into everything.

[LURCH]

I had the first year 2001 700cc Polaris sportsman and it did not have a pull start. For what its worth.