My 2015 1000 is approaching 10,000 miles (currently right around 9500, so first few weeks this spring should get it there). If anybody cares, here's the major issues I've had:
1. Transmission Failure last fall - loud clanking while doing a hillclimb followed by BOOM and then no forward, reverse - nothing. That was a fun 60 mile tow back to camp. This is the only time the machine left me stranded luckily!
2. Rear suspension mounting ears close to ripping off frame. I noticed this while swapping out the transmission - saw cracks in the welds. There was like NO penetration from the factory welds to the frame, the reason they were coming off. I worked with a buddy to re-weld and strengthen and also added in the Cecco Braces I had for the back end at that time. should be good to go now
3. I replaced all bushings like 2 times in the first 4000 miles or something like that. Went to JCCapri bushings after that and it's been fine since!
4. Front diff never exploded - I put the upgraded pinion cover on early in it's life and it has held up well (thankfully!)
5. 3rd set of rear tires now - Kenda bearclaws last but I still burn through the rear tires a lot faster than the fronts
6. Voltage regulator went out twice, I'm on my 3rd now. They don't seem to like sitting above the radiator! This time I went RMStator we'll see how it holds up
7. NO Motor issues - it's still super solid, just regular maintenance. Spark plugs twice so far, I'll probably put another set in early this spring
8. Numerous exhaust issues early in its life due to the bad Polaris design. Fixed after I went HMF exhaust
9. Replaced all the wheel bearings around 8K miles from what I remember. These things last too if you're not running around in the mud/grit all the time.
10. Rear factory shock blew out on a trail - found a used one on ebay and it's been fine since
11. Front lower control arm (factory one cracked after a run in with a boulder - completely my fault)
12. Front coil spring snapped - was out in the black hills with a heavier load on the front end - there were some drops I came off of pretty hard and I think this caused the spring to give up the ghost
Last summer a clutch kit was done on it @ RVS Performance - that clutch kit absolutely ROCKS and the machine still has GOBS of power. I've replaced the drive belt pre-emptively like 3 times, and think I'll do it again this spring.
I'll also have Ryan @ RVS tune it this spring. I have a piggyback on there now for the HMF exhaust - which causes it to run like GARBAGE at altitude. The RVS tune and removing piggyback should help out with this - planning trips to Colorado and South Dakota this summer so it will be nice to have the tune done before then.
All in all, I love this machine and even though you have to maintain them quite a bit to make them last, I always go by the idea that you have to pay to play. I don't think any other machines would have been much better than this one in terms of durability. (well maybe a Yamaha/Honda/Suzuki but they're so boring!)
Any others getting up there in the mileage/hours on their units?
