BOX1

P500 Engine rebuild

Pioneerpilot

Pioneerpilot

New Member
Sep 19, 2021
4
9
3
Mississippi
Ownership

  1. 500
I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!
 
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JenElio

JenElio

NTC's NoMo Chupacabra Caliente!!....
Lifetime Member
Oct 31, 2019
62,444
588,860
113
Loxahatchee, florida
Ownership

  1. Other Brand

  2. 1000-5
I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!
Not sure on the 500 but if you upgrade your membership you have access to manuals and lots lots more info on here.

Also, @906UP is probly the man to ask questions on this project.

Good luck 👍
 
906UP

906UP

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Jul 6, 2017
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The 906
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  1. 1000-3

  2. Talon X
I removed all the body work to give it a deep clean before pulling the engine then pulled it out the top, between the ROPS with a chain fall.
20201229 185207
20201229 183253
 
906UP

906UP

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Jul 6, 2017
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  1. 1000-3

  2. Talon X
I tore mine down, split the cases, pulled everything out then milled the case "bore" to fit the 520 cylinder.

As @JenElio mentioned, a free download of the service manual is available on the site for contributing/lifetime members, I highly recommend it.

20201228 170302
20201229 163431
 
Pioneerpilot

Pioneerpilot

New Member
Sep 19, 2021
4
9
3
Mississippi
Ownership

  1. 500
How was your experience with the 520 kit? Was it worth it? I’ve seen kits available where the cylinder is machined so you don’t have to machine down the case, I would like to do it but it’s looking like that’s out of my budget for now. What did you do for fuel management?
 
Pioneerpilot

Pioneerpilot

New Member
Sep 19, 2021
4
9
3
Mississippi
Ownership

  1. 500
got the motor out just had to take the floor board out and remove the frame under the seat and was plenty of room to yank it out. About to drop off the cylinder to the machine shop and then starts the project of splitting the cases and cleaning out the motor. You can probably guess what caused this project to get started 🍻

A470AB81 0791 4ADC 838E C54DBF3906F6 546FCE3C C7FD 425D 8CB2 8B763EF82602 88CDD7FF 99A7 4C44 9E13 3DEB03F00698 FDE41C4E D05F 4A94 9348 286A3BDE6374
 
906UP

906UP

Well-Known Member
Lifetime Member
Supporting Member
Club Contributor
Jul 6, 2017
12,810
118,970
113
The 906
Ownership

  1. 1000-3

  2. Talon X
How was your experience with the 520 kit? Was it worth it? I’ve seen kits available where the cylinder is machined so you don’t have to machine down the case, I would like to do it but it’s looking like that’s out of my budget for now. What did you do for fuel management?
Not worth the trouble, it might have a little more low end but not enough to notice. The ecu & injector is the same between the 500 & 520 so I didn't make any changes.
 
Smitty335

Smitty335

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Lifetime Member
Supporting Member
Oct 3, 2016
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NWA Arkansas
Ownership

  1. 1000-3

  2. 1000-5
got the motor out just had to take the floor board out and remove the frame under the seat and was plenty of room to yank it out. About to drop off the cylinder to the machine shop and then starts the project of splitting the cases and cleaning out the motor. You can probably guess what caused this project to get started 🍻

View attachment 309972 View attachment 309973 View attachment 309974 View attachment 309975
Deep mud and water are your friend! HA!
 
Montecresto

Montecresto

Montecresto el segundo
Lifetime Member
Supporting Member
Club Contributor
Jan 17, 2016
22,587
34,173
113
Eastern oklahoma
Ownership

  1. Other Brand

  2. 500

  3. 1000-3

  4. 1000-5

  5. Talon x4
I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!
Out of curiosity, why are you rebuilding the motor, did you have a failure of some sort…..🤔
 
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