OPT (sorry for incorrect title) Hey all Im new to this forum. I just recently also joined into the Polaris ATV forum and I was re directed here to get specific help on something. I recently purchased a 2002 Sportsman 500 HO with only 230 miles and 35 hours. It came with a winch, chrome bumpers, rack extenders, rawhide grip tires, etc. I have an issue or two with the machine (nothing serious at all) that I noticed after I brought it home. The brake light stays illuminated as if Im squeezing the brake lever and Im not. I replaced the bulb and its doing the same thing. I took the front plastic piece under the high beam headlight off and disconnected the connector that goes to the switch and the brake light went to normal (dim). When I plugged it back in, it went bright again. Im going to assume that the brake pressure switch is bad. With that being said, it does NOT look fun to replace due to the fact that its surrounded by other parts and it looks almost impossible. I just want to know the easiest way to do it and a step by step process.

Also, sometimes when I am using AWD in forward and go to reverse when parking it in my shed it pulls to one side and the same happens when going in forward for a few seconds. I was told this was sort of normal?

Last thing is my tire PSI. All of my Rawhide grip tires are in good shape but one seems to let the PSI go down to 1.5PSI within a day or two. I filled it up to 10 PSI last night and tonight it was down to 7PSI. I don't see any visual leaks and i sprayed it real quick with soapy water and coulnt see any leaks. any suggestions? I really do appreciate any help and Im happy to be a part of this great forum!

 

I had a slow leak in one of my tires that I had a hard time finding. I pumped up the tire to maybe 20 pounds and put it in my bathtub. I slowly rotated it, flipped it over, and rotated some more. I eventually found the leak and plugged it.

 

You're right the pressure switch is hard to get to. Pull the right front tire allows better access up to the pressure switch.Or you can pull the rack, pop the front panel off and try to reach it from the top. All these hub activated awd systems will have one wheel grab every now and then. First thing I'd do is change the hub fluid and see if it works better. If that doesn't help then the armature plate may have become magnetized. This happens when people leave the awd button engaged and can happen from simple wear over time. Item #4 in the parts break down.2002 Polaris SPORTSMAN 500 ALL OPTIONS (A02CH50) Front Wheel All Options | Cycle Parts Warehouse Plus might as well change both out as the other side usually does the same thing later on. Not that expensive.ARMATURE PLATE FITS POLARIS SPORTSMAN 500 1996-2002 | eBay To help with repairs and service this manual is the best 5 bucks you can spend.2002 Polaris Sportsman 500 Service Manual PDF Download

 

Right front tire? it looks like the front left would be a better view but ill try. Either way it looks like no matter what way I have to get to it, it will be hard. What do I disconnect first? Will I have to bleed my lines from air in the system? It looks like there is a plate between the switch and the block where the lines meet up. Is there any way to wire it so I can just delete the switch and have my brake light work some other way? also the armature plate if I decide to do it (which I probably wont because it really doesn't give me issues only what you call "every now and then") is it a tedious job to do? I will be changing all my fluids because even with low miles its the age that makes fluid bad. All in all its a great ATV but these couple small things drive me crazy because I want it PERFECT!

 

Sorry when I said right front I meant looking at the machine from the front..If you want the machine perfect then it may takes a little work on your part. All you have to do is unplug the wires from the switch,unscrew it and install a new one. Easier to do it right than to try to someway rig up something else to trigger the brake light.Yes you might have to bleed the brakes,but possibly not,all depends on how quick you can swap over the switch. On the armature plates sometimes a good fluid change can solve it. If it continues to lock up,then the manual goes into good detail on how to service the hubs. So does this video as the guy uses the manual as a guide. The pressure switch from Partzilla is 22 bucks.

 

This video is a scrambler? It applies to me too? Also when I change the hub fluid should I change the fluid in the front differential? When I go to unscrew it I shouldn't have to touch other brake lines right? Just unscrew it and replace it? What is the easiest way to unscrew it because it does not look like I can get a socket or anything else for that matter in there.

 

Awd is the same on all hub models.. Yes best to replace the front diff fluid,shows 5 ounces,but usually all you can put in is four ounces after draining. Regular old 75/90,80/90 gear oil is fine.Nothing but the switch and it's wires have to be touched.Vice grips or channel lock pliers on the switch body.

 

Ok, Is any fluid going to come out of the block when I twist off the switch? If for some odd reason when I put a new switch on and the brake light does the same then what? I'm just expecting the worst here that's all. Also for the hub fluid and differential fluid can I use the fluid that they offer at the dealer for new Polaris Sportsmans or no?

 

If the switch doesn't solve the problem,then you'd have a wiring short somewhere..That's something that you should have checked out already. Always Demand Drive Plus for the hubs. On the simple ring and pinion front diff you can use any brand of diff fluid like I mentioned.The Polaris "Angle Drive" fluid is basically the same as any 75 or 80/90 gear oil. Save your money on what Polaris wants on this. Just get it at any auto supply.

 

Well Like I said when i disconnect the switch the light goes back to normal and dim and when I plug it in it brightens up as if I am squeezing the brake lever when I'm not so could you tell me something about that before I buy a switch? Also I will make a trip to Autozone or Oriellys and ask for any 75 or 80/90 gear oil and ill be ok? wont make any noises due to non Polaris fluid? Whats the better choice 75 or 80/90?