Hi all, great forum here! I've found some good info on my leaking carb. I've had a 2000 Polaris Sportsman 500 4x4 for 10 years. It has only about 1500 miles and 215 hours. It runs great, pulls heavy loads, gets up hills, its lots of fun! Question: in preparation to bring this quad in a container to Costa Rica with me, what maintenance or re-building of parts/systems should I take care of here in the US before I move?

1. The carb rebuild is already on my list
2. I'm adding street legal kit - directionals, horn, mirrors - so I can plate it
3. Silencer / muffler. any recommendations on a replacement - to give me best chance to passing emissions? One good idea was to get a California emissions silencer which I haven't found, or any aftermarket for that matter. Maybe just buy a new OEM? Not cheap - they're $240
4. New tires
5. change fluids - engine oil + transmission oil, flush brakes
6. It works great and has low miles. should I consider water pump overhaul, brake caliper overhaul, water pump.... all this good stuff. Of course I'd prefer not to but at what point do these items tend to fail?
7. Any tips for finding new plastics? Can't find any OEM, or aftermarket plastics, just overpriced crap on ebay.

Thank you!
Patrick

 

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