I am probably going to buy a 2005 Sportsman 800 with 1330 miles tomorrow.

Would you please list for me the known issues with this machine.?
He says he didn't have any melting plastic.
It was manufactured 5-13-05. That seems like one of the first ones.

Thanks.

 

melting isues w/ small hat sheilds and fuel pump problems on a few,

 

Thanks stendori. I noticed in your pics you replaced a cv/axle. I have to do that on this used one. He says one of the rears is bad. Is it a hard job. What tips do you have or things to watch out for in that process of replacing the rear axle?
Thanks.

 

Looking again in the archives it looks like some people had troube with the front engine mount breaking.

Any other problems?

 

You might have a problem with your friends trying to keep up with you...[img]i/expressions/face-icon-small-happy.gif[/img]

John

 

on some 800's they broke the front motor mounts, but there only rubber mounted to a steal plate which seprates. i didnt have one break on either one of my 800's yet. as far as the cv joint there not too hard to get out. is it clicking or boot ripped? the biggest thing i'll tell you is to make sure that your radiator is kept 100% clean so it wont over heat from baked on mud, front and back. its pretty straight forward on what to unhook to pull the rear cv joint out to work on it. it just snaps out and sometimes needs to be pryed.

 

The CV is clicking.
Do you just replace the CV or the whole axle on that side?

 

Go on ebay and look at replacing the whole shaft, there is a guy who makes stronger jouint and shfts for lkike $149.Think he's called the cv guy or cv repair.

 

"THE CV MAN" www.cvman