I have a 2000 Sportsman 500. It seems like something is always breaking on it. I just got my clutch and belt replaced and now I need to rebuild the carb on it. There are also a number of other minor things that I need to fix like headlights, the temp sensor for the fan, the recoil starter, the winch, etc. It seems like the list is never ending. I bought this used about 5 years ago and have put about 1000 miles on it since I got it. It had about 3000(maybe more) on it when I purchased it. The last 2 years, I have had to work on it more than I can ride it. I think I have actually only gotten to ride it about 3 time in the last year as something is always broken.

Should I just sell it and get another one, or should I keep after it. I am almost at the point of giving up on it. How many miles are quads usually good for before sending them to the junkyard?

 

We have close to 8000 miles on our 97 Sportsman, I changed two u joints a bendix, 2 batteries ,drive,two lower light bulbs ,temp rad sensor and 3 belts. Not bad, but I grease it regularly. I silicon the pull start handle in place to make the recoil cover water proof, that way your not recking the Stator, recoil,bendix and pluse coil with dirty water,water will always get passed the handle in factory mode believe me.

My 2001 has 2600 miles and I just changed the tires , belt ,battery once and clean the starter brushes.

 

I have a 2000 Sportsman 500 as well. It's had similar issues over the years, but all in all, is a good machine. I guess you have to look at it this way...are the repairs cheaper than buying a different machine?

 

Light bulbs and belts,tires and batteries,brake pads have to be changed on any make of ATV you can not even count them as a problem. Winches do not last long on ATVs even if you do not use them much and are not really concidered part of the ATV.

My Warn winch puked after being used 7 times tops, I plame Warn for that POS not Polaris.

 

Other stuff broken / needing fixed on mine:

Front right wheel will not engage in 4wd (bad hub?)
Lower steering bushing needs to be replaced (the steering is very sloppy, rivets on the mount are loose.)
Rear wheels seem to be locked together now(just started)(difficult to turn on loose gravel)
The fan is rigged up to a toggle switch because it will not come on automatically
The front left strut locks up frequently
The entire area inside the recoil starter where the stator is, is completely rusted out from water getting in.
Looses water from the cooling system while running.
I need to replace all the fairing screws with something better. They are currently a mixture of random screws, nuts and bolts and come loose often
Lots of electrical gremlins. It seems the previous owner did extensive rewiring for an unknown reason.


Stuff I have fixed in the last year(that I can remember).
Replaced all 4 tires
Replaced primary clutch and drive belt
replaced battery
replaced front right strut
rigged up toggle switch for fan
replaced head gasket
fixed bendix
fixed lots of leaks in the cooling system
replaced the carb. intake boot.
replaced starter solenoid
Rear "A" frame bolt sheared off

It just seems like every time I fix one thing, something else breaks immediately afterwards. I would like to be able to fix it up enough to be able to sell it, but it won't stay fixed that long. It sat up for about a year at my uncles house and while it was there, one of his (friends) was "borrowing" parts from it. My uncle did not know about it. The guy replaced some of the stuff he took off, but not all of it so I still find things missing here and there.

I will say about it that when it runs, the motor runs very strong, especially for a non H.O.. After I replaced the belt and clutch, even with a bad carb on it, I can pop a wheelie. The motor always starts up, even after sitting for a long time, although nowadays it seems to like a quick shot of ether or carb cleaner to get going. It has only left me stranded once, unfortunately that was on the first day of a 5 day trip out of state. I lost 3 days of riding because of that. That was because someone before me had put in a bolt that was to short on the rear A frame and it sheared. Every other time, it has at least gotten me back home, however, it is usually just limping along.

As far as repairs being cheaper, I am thinking they are getting real close to the price of a new(used) machine, especially if they keep going the way they have been.

I am not sure if what I am dealing with is a normal amount of maintenance, but it seems excessive to me. I usually have very small windows that I can ride in (maybe one or two weekends a month), so I am thinking if I had something more reliable, I might be able to ride more.

 

Front right wheel will not engage in 4wd (bad hub?)

Needs fliud or no power to hub.


Rear wheels seem to be locked together now(just started)(difficult to turn on loose gravel)

Impossible all ATV rear wheels are locked in unison, most likely one of the front bubs are not releasing.


The fan is rigged up to a toggle switch because it will not come on automatically
Rad sensor or connection is bad.



The entire area inside the recoil starter where the stator is, is completely rusted out from water getting in.
Thats where siliconing the pull handle in place save alot of grief.

Looses water from the cooling system while running.

Water pump weep hole,needs seal replaced or hose connection.

 

Oh yea, forgot that one. I also replaced the water pump and seal about a year and a half ago. It stopped leaking from the weep hole, but is still loosing water somewhere.

I guess I will stick with it a while longer. I would just like to be able to ride it every once in a while instead of always working on it.

My dad has a 2005 800 sportsman that he won from his work a few years back. It has 27 miles on it. I am trying to talk him into selling it to me for about $3k. That is all I can afford now. He is trying to sell if for $6500, but hasnt' had a single serious offer in over a year so I am hoping he will cave.

 

since you already invested a decent amount of time and money, personally i would keep fixing it till it is good. i am stubborn, though. i was rushed to buy a truck a few years back and bought one without testing it out first. paid 5400 for the truck and have since put well over 7500 in repairs and labor in it. but i am keeping it because 1. i know everything works on it and 2. it is worth more to me then i would get for selling it. just something to think about...

 

Tell your dad that I'll give him $3100

 

I also have a used 2000 Sportsman 500:

I have replaced:
both front struts and springs
rear shocks and springs
radator fan sensor
speedo cable
one belt (needs another and maybe a clutch adjustment)
battery and cable
a bunch of fender flare screws
all of the fluids at least once (just because)

Stuff I fixed:
starter bendix, had to replace the recoil gasket
front hubs were dry (filled with front hub oil, then realized I filled them and you are only supposed to install a smalll amount)
just broke a rear suspension bolt, have to get the bolt out

I have invested too much in mine!

Steve