Knowing I cleaned the grease off the diff splines and transmission spline do they look good.

 

I've never had to replace a transmission shaft or the pinion shaft in the differential for stripped splines,but changed plenty of prop shaft assemblies. The shafts look ok.Just keep the new prop shaft greased..

 

Awesome thx your a great help on here.....I appreciate it....

Scott

 

I am having problems with my 500. I recently had the ecm replaced under recall. After a month or so of using the bike it is starting to act up again. Battery light comes on after a short period of time driving it and will come off and on. If I shut the bike off it will not start back up. I am driving it in temps below 0 degrees, also recently replaced the starter. So I am led to believe that the battery is not being charged while being run so the bike will not start back up, but if I put it in my heated garage it will turn over. I recently put a brand new battery in and this is the first time this issue came up. Also the dash isn't always lighting up on the bike while trying to start or turn the ignition. Has the replacement ecm crapped out?

 

Sounds like it.. It's not uncommon for the US made ecms to fail same as the Chinese.Once running check charging rate at the battery.If less than 14 volts,then probably need to get another one.Depending on how long ago you had it replaced under the recall,the dealer might be able to go to bat for you on another one. Polaris only allowed one replacement,but dealers can have a little sway on this if they try.

 

It has only been a month and a bit with the new one.. Checked the battery, it's at 12.4 volts at idle and 12.8 volts with some throttle.

 

Sounds like another ecm bit the dust.. Dash lights are on a different solid state breaker in the ecm,but you can eliminate a stator on charging problems to be sure on this part. Check that all yellow wires from the stator leading into the ecm show about the same amount of resistance between each other and no yellow shorts to ground.If they check out the ecm needs to be replaced again.

 

Does anyone have a copy of service manual for 2005 polaris sportsman 500 ho. Thx guys

 

If no one has one they can share with you,here's one for 5 bucks.2005 Polaris Sportsman 500 Service Manual PDF Download

 

Hey bud so I metered the yellow wires to ground and there grounded. Also metered between each yellow wire and there grounded as well so it's probably the stator. I just found out where the stator is located and should have put 2 and 2 together when I changed the starter and bendex and had broken pull cord sleeve we jb welded. So probably all the water that got in there ruined the stator as well. So does this all sound like a bad stator???