I'm currently tearing down a 2001 4x4 Scrambler 500 that I bought as a project. The transmission would not go into forward was the main reason for the guy selling it "as is". So far I've notice a few interesting things:

1) page 8.2 step 6 should say "remove exhaust pipe" not "remove carburetor" in the transmission removal section
2) the starter is appears to be exactly the same as the one on my 400ex, it's the same manufacturer and and model number as well (sm-13 as I recall)
3) a good clutch puller can be made by buying a high-quality 4" 3/4-16 bolt and a 5-1/2" 5/8 bolt, cut a 3-1/2" piece out of the non-threaded part of the 5/8" bolt and grind the ends smooth and slightly tapered, stick it in the center hole of the clutch followed by the 3/4-16" bolt, tighten the 3/4 bolt until the clutch pops off, cost was $9
4) the swingarm bolt is HUGE, 1-3/4" socket, AutoZone sells a decent one for $9.99 if you need it quick, you may need the 1/2 to 3/4 drive adapter for $4.99 if you don't have 3/4 drive tools

I tried to buy the Polaris puller locally but they would not sell me one. I can order you one the guy tells me on the phone. That's great I told him. Sometimes I think these guys don't realize that anyone can order anything these days. I pulled the transmission and drained the oil. No metal in the oil so that is a good sign. The stuff behind the recoil housing is very rusted so it's going to take some work to clean that stuff up. Anyway, so far so good.

-Jim

 

Most people don't think to "seal" the pull rope after starting it. Not saying you did this, just adding to your observation list[img]i/expressions/face-icon-small-smile.gif[/img]

 

Good point. I never did that as I never rode it. I'll keep that in mind when I get it into riding condition.