Hello all,

I just purchased a 2010 Sportsman 500 H.O. I grew up on atv's sold my '96 sportsman about 10 years ago and have finally returned to the atv world.

I got a great deal on this machine but it looks like she has seen some rugged use so I'm sure I'll have a few kinks to work out to get her ship shape. Just wondering if anyone here knew of any common issue these machines may have.

First the high beam does not work, have a feeling it will be a chaffed/cut wire and should be an easy fix, just didn't know if there was anything else I should be on the look for...

Thanks

 

for the most part the 500 has been the flag ship for Polaris and probably the most reliable. I can't think of any issues other than normal wear and tear items on the 500.

 

welcome to the forum. if it hasn't already been done, i would do a complete service to it. also unlike your old 96' this is a totally new awd system to you so be careful you DO NOT put your bike into awd while the back wheels are spinning(like when your stuck) or you will easily damage the roller cage in the front end. you can throw it awd while your moving down the trail w/ out any issues or even leave it into awd full time(i never do myself)w/out any worry of harm. check your cv boots for any rips or tears and replace if you find any. any questions feel free to ask, as the forum is great for good info for ya.

 

Welcome back to the scene!

 

Pretty well the same ATV as your 96 sportsman 500 with the plastics off.
improvements made were a larger carb and performance cam for more power.
No u joints, all stronger cv joints now.
More suspension travel up front.
Maybe 2 grease fittings at most not 27 like on the older model.

improvements to for the worst.
Single Hillary with a plastic roller cage in the front diff,not two metal ones in each hub any longer.
Smaller gas tank.4.1 gallon rather then 5.25 gallon. don,t expect 100 miles plus on a tank any longer.
Digital speedo has to work to have AWD,where as the older cable speedo can be smashed off in a roll over and not effect the awd.
ECM brain box controls way to much, if it fails your dead in the water.

I think they do not have a pull rope back up any longer as well.

 

Opened up the headlight pod and found a broken wire, repaired it and viola working high beam headlight!

I noticed the digital tach doesn't work.... anyone know what may cause this? another broken wire?

 

Pull the harness connector on the speedo and one red wire should have power at all times for memory. If it doesn't have power on the red wire,it could just be another short causing the speedo problem like the headlight wire short.With the igniton key on also, the 16 pin harness connector should have 12 volts on pin 1,pin 2, and pin 8 (which includes the red memory wire) . If it does then the speedo could be faulty. Plus jack up the front and back and see if you still have awd. If it doesn't you can jump the brown/white wire to a brown wire in the speedo harness and least have awd untill you replace the speedo.The awd system is routed through the speedo also which is stupid imo. OPT

 

Thanks for the advice.... I definitely have AWD.... we currently have a lot of snow around here and I've been testing it out in my yard! Speedo works(its not digital) and all the rest of the digital display seems to work fine... odom, miles,hrs, fuel gauge all work fine.... not overly concerned about having a working tach but if its an easy fix I'd like to have it working.

I just noticed today that it pulls to one side when giving it throttle in awd... don't know how I missed it when looking it over before buying but one of the front a-arms is bent ( has obviously hit something fairly hard) all else looks fine just will have to replace the a-arm, no biggie.

A stupid question before I order the wrong one.... if your looking at the machine from the front it is the a-arm on the right side....This would be the "right front a-arm" correct? or is that based on if your sitting on the machine? just want to get the correct one coming! found them for $89 online.

 

Parts are viewed as you are sitting on the machine. This would be the left arm that you need. OPT

 

Really a GREAT opportunity to change ALL fluids. Have fun...and enjoy! Post pics...when you get a chance...


biz