P500 Just Bought a Pioneer 500 Project

[jimz49]

Recently bought a 500 that has a leaking head gasket and an issue with the 4th gear in the transmission. I did the radiator leak down test and from all indication the head gasket is leaking. When I drained the oil it had that look to it that anti-freeze had gotten into the crankcase. That's one of my issues.

The other issue is it doesn't want to stay in 4th gear. The other gears are fine. When trying to shift back into 4th the gears grind. Not sure what it is but hopefully will find out when I disassembly the engine.

I currently have the engine on my workbench waiting for an extended period of warmer weather.

Does anyone want to take a guess what might be causing the 4th gear issue? Will report back once I start taking the engine apart and let you know what I find.

The picture was taken by the previous owner before I bought it.

Which brings up a couple more questions. As you can see someone during the 500's life decided it was a good idea to hack the front bumper. Are there any suggestions for a replacement? Should I look for an original or go aftermarket?

Thanks for any help or suggestions that you may provide.

 

[Admin]

 

[Moark Willy]

You can get a winch ready bumper from UTV direct for about $250.

 

[silvertrd09]

Welcome from TX.
On the clutch, may not have enough oil in it. And you might have to adjust the clutch (clutch adjustment screw) under the seat. Should be explained in owners manual. Did you get one when you bought it?

 

[jimz49]

Moark Willy - thanks for the EMP bumper info. Shortly after I posted here I found an OEM bumper on the local facebook market place. That is a great price on the EMP though.
Silvertrd09 - I have a owners manual coming, but did not get one with the 500. However, I have watched a couple youtube videos showing how to adjust the clutch. But shouldn't an out of adjustment clutch affect all the gears, not just the one (4th gear)? The oil level was fine when I checked it.
We've finally got some decent weather here in PA and I'm just about ready to start disassembling the engine. Probably in the next few days. When/if I discover the problem I'll report back and let everyone know.

 

[silvertrd09]

Yeah it would make sense if all gears were grinding but the gearing on the p500 is different. 4th gear trys to be like 3rd but it's really like 5th in drag. Like dragging a boat anchor looking for his friend number 6. I kid I kid 🤣,
There is a procedure for checking the oil level. Warm up the engine then let it sit 2 or 3 minutes. Put the dipstick in but don't thread it. Maybe over fill it a tiny bit. Maybe use a heavier weight oil in the summer. Hopefully 4th still has all his teeth.

 

[jimz49]

I didn't know 4th acted differently. Wish I knew before removing engine. I still need to do the head gasket, but could have done that while engine was in place. However, it's on the bench and I'm determined to take it apart to see what's inside.

 

[Hello_Darkness]

Yeah it would make sense if all gears were grinding but the gearing on the p500 is different. 4th gear trys to be like 3rd but it's really like 5th in drag. Like dragging a boat anchor looking for his friend number 6. I kid I kid 🤣,
There is a procedure for checking the oil level. Warm up the engine then let it sit 2 or 3 minutes. Put the dipstick in but don't thread it. Maybe over fill it a tiny bit. Maybe use a heavier weight oil in the summer. Hopefully 4th still has all his teeth.

These aren't oil dependent for shifting, don't get me wrong low oil can cause issues with clutch performance but not like the 1000 or 700 series engine

 

[jimz49]

Have an update on my progress with the P500. I have the engine apart and the transmission removed from the case. I visually inspected the gears, shift dogs and main and countershafts. The only thing that I have a question about are the third gear dogs on the mainshaft. The dogs look worn to me, but I'm not sure what they are supposed to look like. However, If they are worn it would explain why the transmission would pop out of fourth gear. From what I can tell the third gear dogs lock up third and fourth gears.
Take a look at the attached pictures and let me know what you think.

 

[jimz49]

Here's one more picture. Trying to get a closeup.