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Hi All

I have been plunking around with Polaris for about a Decade, I like to restore some of the older Models. I have started my next Project which is an 05 Polaris Scrambler 500 HO.

There are some pretty potent upgrades that you can do with these older Models. The first is getting a Better Rear Shock. If you have the long travel suspension, there is another Shock that you can pull from Polaris Outlaw that will fit. You need the rear shock from the Outlaw that has a straight axle rear end. Not the one with IRS.

The second is upgrading the Transmission with Low-Range. You can pull this from a Polaris Explorer 400. Years 99 to 02 I believe. This will bolt right in, you just need to fab up a shifter mount or you could just fab up your own secondary shifter mechanism. I have heard that the Polaris Explorer 250 has a different gear ratio and you would lose some of your top end speed if you pull a donor from a 250.

Anywho, just wanted to throw these tidbits out the for anyone else who wants a shock alternative or transmission upgrade

I'm a pretty big guy, so I have the tension set pretty high. this helps eliminate the squat in the rear end. Something I used to never have any control over.





pic of the Transmission installed. You can see the 2nd post for the second shifter shaft.

Sorry, dumb questions today. I'm a new quad owner and picked up a 2003 Sportsman 400. Recently had my oil sump explode due to cold freeze up (a whole other story). Thought while I'm fixing that, I would change out the fluids as I'm not sure when the previous owner did them.
I'm confused as to what goes where. I have Polaris fluids. After watching some youtube vids on changing fluids, I thought I had it down. Now, I'm not sure as mine is older and I'm not certain I should be using the same fluids as the new models.
As of now, I have a bottle of Angle Drive Fluid, AGL and Demand Drive fluid.
I'm pretty sure the AGL will take care of my transmission fluid change. I've seen video where one guy put Angle Drive in the rear differential and Demand Drive in the front Diff (may have been 2004 or newer). Saw another video of a guy putting Angle Drive in the Front. My owners manual makes it seem AGL for all three and a fluids chart from Polaris shows AGL for Transmisison (All three seem to agree on that one), but shows Angle Drive (says front) but also lists Demand Drive but doesn't say where.

Can someone tell me which fluid goes in each of the three places on this older model Sportsman? Really appreciate the help!!

I have little droplets of coolant leaking out of my water pump, I take it it’s a bad seal? Is it okay to run it for a day?

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Posted this in the clutch section but didn’t receive much feedback.

I just got a .125” spring spacer from STM to install in my primary clutch. This will be going on my ‘17 570 outlander.

Looking for advise on how to install this. Also what tools I will need.

Never had this clutch apart but im not afraid to tackle it, Ive taken my snowmobile clutches apart in the past so I have some idea.

Thanks guys.

Would anyone in Texas, preferably South Texas, be interested in trading a stock muffler for my AAEN muffler? Nothing wrong with it or anything of the sort, but for my purposes for my Polaris, its entirely too loud. Not looking for cash on either end, just a straight trade, good condition for good condition.

My machine is a 2007 Sportsman 800 if it matters.

My friend picked up the quad for me so I haven’t seen it yet but I want to go through it when I pick it up next week.

My questions revolve around servicing/changing the fluids, checking valve clearances, cleaning carb(s) and greasing pivot points etc.

Are there any important differences between series run from 2002 to 2004 to be aware of when looking for parts?

What are some problem areas to look at and what type of lubes are recommended for the drivetrain etc?

Thanks,

Joe

Hey All,
So I have a 18' 850 SP with the arched a-arms. I ordered front and rear guards off of Babbitts that they said would fit. Part # 288067 and Part # 2880644.

These seem to be for flat arms and I'm not sure they fit my vehicle. I don't want to completely tear the packaging apart that holds all the bolts and nuts if I have to return them. After some more searching it seems like these are for the xp regular a-arms and don't actually fit my quad.

Can anyone offer any input into this? Is there a part number for the arched ones? Do I need to go totally aftermarket?

Thanks in advance!

I want to give my opinion on the SuperATV Assassinator, specifically the 29.5x8x14's.

The tire measures a true 29.5" tall at 7psi, and weighs in at a decent 53 pounds.

Some back story; My bike came with 33lb 28" ITP Mega Mayhems, so the weight difference wasn't very noticeable (7% change in final drive ratio, 46% heavier), though it has helped unsprung weight and lowering the center of gravity. I picked up these tires and a set of rims online, and installed them on my 650. Initial results were incredible, as they pull and pull through places I BURIED my bike weeks before. Without touching the clutching, the bike is quicker as it can now put the power to the ground.

Lets start with mounting. I mounted these on standard 14" 5+2 wheels by hand, with little difficulty. I used dish soap and tire irons, with each taking about 5 minutes max. Seating the bead does take some patience and a high flow of air, make sure the tires are warm or they are stiff and impossible to seat.

Hard pack/road riding: Gravel does get a little squirrely above 70kmh, but with such a small contact patch, that's not at all surprising. On the road they grip and hold, and they are very smooth, with just the typical knobby-ness noticeable only below 5mph and a small vibration/shudder in the bars.

Grip: Mud, check! Snow, Check! the only place these tires arent the best is pure ice, which again, is expected. If you have snow, mud, grass, stone, or anything it can grab in front of you, you can bet they will hook up and send it out the back as you power up and over or through everything. I have yet to get stuck with these tires.

Down Side: These tires if you are throttle happy and stuck will dig everything out from under you. Throttle control will take you anywhere though.

I hope that helps any of you with the decision, as there arent much for reviews out there. Oh, and no they dont rub anywhere on my outlander :grin

Koomafloo.

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Have a 2016 650 Outlander DPS kept at my cabin in Utah. Only has around 300 miles since I bought it new so not much experience with it. Mounted a Denali plow on it for 2018 winter and we got no snow last season.

We've made up for it this year. Got to cabin last night around 9 PM to find a foot or more of layered, ice hard frozen snow on steep driveway. It struggled a bit pushing a blade full uphill but made short work of clearing a long, steep driveway so I could get my truck up towing a heavy utility trailer loaded with flooring and my son's quad.

This quad is a beast at nearly 65hp!!! My son's new Polaris 450 has 33hp and you can feel the difference just driving it around with no plow on it at all.

Loving this Can Am!!!!