I had this up off the ground and was checking for any movement in the bearings. On one I found a little movement and checked the nut, but it was good, yet the whole wheel still had movement. You could see it rocking in the strut. After I removed the hub assembly, I noticed that the strut seal sleeve had movement. It was loose where the silicone holds it to the strut. What should be done with this? I've read here that it's not an easy task to install one of these. My local ATV dealer has no interest in doing it either.

 

Not that hard with the manual. You have to use a thin sharp punch to remove the sleeve without gouging the strut casting. Usually you have to replace the coil as the plastic face cracks also. Clean the excess silicone up,install the new coil,silicone the strut area,tap the new sleeve on with a block of wood. Just make sure the sleeve is flush with the inner pole of the strut or no more than .001 clearance.A lot of dealers don't want to repair because it's easier for them to sell you a new strut assy or some may have never replaced a sleeve to begin with.

 

Thanks OPT. I really didn't want to ask the question yet again that you've answered so many times already. I just wasn't sure about the loose sleeve and why the spindle/axle was loose when the nut was tight.

I've looked online for manuals, ( I had one, but we moved last spring and can't find it anywhere) and all I've seen is the Clymers. Is there a better one I should be looking for, and where might I find it?

 

No more free ones that I can find. Maybe some else has,but here's a good pdf service manual for 5 bucks. Most people just print off pages as they need them.DOWNLOAD 1996-2003 Polaris Worker/Sportsman/Xplorer 400/500 Repair ...

 

Thank you!! Time to get to work.

 

How do I know which one I have in this list for ordering parts? On my title it has A00CH for the model. Is it on the quad somewhere?

2000 A00CH50AA SPORTSMAN 500
2000 A00CH50AB SPORTSMAN 500
2000 A00CH50AC SPORTSMAN 500 RSE
2000 A00CH50AE SPORTSMAN 500
2000 A00CH50AF SPORTSMAN 500
2000 A00CH50AH SPORTSMAN 500
2000 A00CH50AJ SPORTSMAN 500 RSE
2000 A00CH50AK SPORTSMAN 500
2000 A00CH50AL SPORTSMAN 500
2000 A00CH50EB SPORTSMAN 500

 

Doesn't really matter as the the different numbers besides A00CH50 just stand for body colors for the most part.All the hub parts are the same. Here's a cheap place to order parts.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

OK, and thanks for the link!

 

Well, I got'r done OPT. Works like a charm. It was intimidating at first, but when you have a great instructor, what's there to be afraid of.

Thanks so much!!!

Now. Before I started this, I had a slight looseness in the side I worked on. After re-doing the coil and sleeve,(realizing they have nothing to do with it) the wobble is still there. The movement is no more than 1/8 inch. The axle is included in the movement. There is no movement in the ball joint and the bearings look great. From how I see it, if all the bearings are pulled tight on the axle, it shouldn't be doing this. The axle nut is tight to 12 ft. lbs.

 

Have to consider a little wear in the bearings and races(2 in the hub,2 in the strut) along with any give in the cv joint can cause a little movement. No more than 1/8" I wouldn't worry about it. Later on if you want,you can pull the hub,knock the races out and install new bearings. Even then you may still have some slight play from the cv. Main thing is that the awd works ok and to not tighten the hub nut further.