Well its kind of a long story, so I'll try to sum it up best I can. I have a bought new, 04.5 sportsman 500 thats with the inline shifter. The whole time I have owned it there was a lot of extra noise and popping clunking sounds from the drive train. While at the dealer for a waranty replacement of the drive belt at less then 200 miles, they assured me everything was normal. Well about a month ago while turning something staped in the transmission/rearend. I had to take it back in 4x4 with just the front wheels pulling. I have taken the trans assibly out. Removed the ~20 some bolts in the case. I just can't figure out how to seperate it, I looked on both sides of the axle for a snap right but I cannot see how to seperate it. Some one who has had a problem like this of that has a repair manual could you try to point me in the right direction to get it apart. Any help is greatly appericated.

 

So no body knows anything about it?

 

I would go to partsland.com and look at the free parts breakdown for your machine. I've torn down two Sp500's (1999's) and best I can remember, the metal dowels were hard to break free. Once the case began to split there wasn't any surprises inside... [img]i/expressions/face-icon-small-wink.gif[/img]

 

ive encountered this same problem with my 700.
lots of clunking when going into gear, then shortly after while doing a wheelie, it just revved up and sat down.
putted home in 4x4 with the front tires only.

any advice you can give me on the outcome of yours?
thanks!