Just bought a 2006 Sportsman 500 EFI but the front wheels wouldn't pull. Long story short, the PO let ALL lubricant run out of the front diff. It is BONE DRY, crusty inside, and will hardly move. It makes a grinding noise too. I haven't split the case open yet but was thinking I may be better replacing the whole assembly rather than rebuilding one that has been ran dry. The pinion has some wobble. How much is normal?
The complete unit model # is 1332428. Can anyone tell me if this front housing is the same as the one on other sized Sportsmans (400, 700, etc) or if it is specific to the 500?
Any other insight is welcome...

 

Too bad about your situation.
Check out PurePolaris for part #'s and then scan for other years to see if you match up.

 

you can use any front end from say 05' to 08' from the Apt330 including all the sportsmans 400,450,500,600,700,800 and the ranger as well.

 

Your roller cage probably just needs replacing. Though not cheap it still is cheaper than replacing the whole front diff.

 

If you're going to replace the whole diff check eBay. I know there is a couple 800 diffs on there. I agree that it would be cheaper to rebuild. Take it apart and check it out. You can rebuild it and if it works you saved yourself the extra$. If it doesn't there is always some on eBay. I think I have a brand new bearing/seal kit sitting in my garage still in the package that never got used on my 05 800.

 

Thanks for that info. I saw those on ebay for '06 800 but wasn't sure if all models used same gear ratio, etc...

I'm at J-O-B today so no progress on the bike. We won't know full damage until I open up the case, but I expect the gears to be messed up too. The pinion has a good bit of wobble in the shaft and the bike would hardly roll forwards or backwards. What's the chances of the armiture also being damaged? Before I took the bike apart, I measured 28 ohms from the plug.

 

i wouldnt do anything al all until you get it open and maybe as tlc says it might be just a cage needed. take it apart and clean it up and then see. imo

 

I head that changing the roller cage is not that bad of a job.

 

Where do you begin?....Split the case or remove the pinion cover 1st? Is anything spring loaded or going to jump out?

 

Part #10 $190 is the problem usually. Here is the price list.http://www.cyclepartswarehouse.com/f...2006&fveh=7107