I am wondering if I can get some input on the differential in my 2007 sportsman 500 HO EFI. It has been an ongoing problem; heavy steering, binding, and pulling right or left. The AWD has always engaged/disengaged properly though. I had a really hard ride the last time out and I thought it was time to investigate. I pulled the diff and a piece was twisted and torn in a few spots, both output hubs have worn/torn spots, and some of the pins that stick out of the ring gear are gone.

Are the pins in the ring gear replaceable?

Is the wear on the outer hubs too far gone?

Is this more money in parts then a complete remanufactured diff?


Thanks for your input

Pictures Below:

http://forums.atvconnection.com/pict...ictureid=45518 http://forums.atvconnection.com/pict...ictureid=45519 http://forums.atvconnection.com/pict...ictureid=45520 http://forums.atvconnection.com/pict...ictureid=45521 http://forums.atvconnection.com/pict...ictureid=45522

 

Doesn't show that they are. Comes with the pinion gear assy,plus both ring and pinion need to be replaced as a pair or they wont last also.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Almost as cheap to replace the whole differential.
Might be better in your case to give this place a call to see what they offer.Rox Technologies :: Polaris

 

Thank You Old Polaris Tech for your post. I will try and find a complete gear box for this thing. It sucks because the old one still works; but for how long is the question. I apoligise for my duplicate post.

 

OPT,

I am wondering what the significance of the clutch basket housing is? It is not offered as a replacement part, and on the Polaris microfiche it sais to discard this part when replacing the internals. See Microfiche attached.

Also, how are the tiny roll pins supposed to be positioned in the ring rear? (how far should they stick out, should they be flush?) Other then the outer hubs the only visible damage is to parts that I cant replace (clutch basket spacer& small roll pins in the ring gear), it is frustrating.

If I hammer this thing back together and use it, is there any severe consequences if/when it malfunctions like leaving me stranded on a mountain top?

 

This was kind of a work in progress from Polaris when they eliminated this part when the front diff was opened up for repair. After seeing the pics of the damage to yours,it's not worth the head ache to continue to try to save this diff especially since the ring and pinion gears are involved also. Just my two cent worth on this one.