I just got back from riding my new Sportsman 500 through the Rubicon Jeep Trail. The ability of this quad to go through a trail that's filled with beach ball size boulders is amazing. But therein I found this quad's weak link--the front hubs. They stick out about 5/8 of an inch beyond the rim. You can forget about squeezing the Sportsman through the rocks because the outside of the hubs will get damaged. I learned this the hard way--with my hub oil spilling out. The outside cap appears to be plastic, and only suffered minor scrapes. They aren't disfigured at all, but they're both leaking where they seal against the metal hub body. What a joke. Anyone out there had this problem? Are there deep dish rims available that will cause the hub to be more recessed, and thus not so vulnerable? And if so, are there any drawbacks to this fix?

 

Wiley C

I think that the 04.5 sportsman models adressed this problem going to the same style of diffrential as the 600 & 700's use. My 04.5 hubs don't stick out past the stock rims.
Offset wheels will solve the problem but will also increase wheel track. May have to climb around the objects instead of squeeze between them.

Hope this helps


Rider

 

Yeah, I should have waited for the 04 1/2 model year. They made some good improvements. Most notably the new shift pattern (my shifter is notchy and difficult to engage), and the new hubs.

I took the hub caps off. They look fine. I don't think scratching the caps had anything to do with why they're leaking. What I did find was RUST where the O-ring seats on the hub body. Rust! Can you believe it. I just bought this machine two weeks ago, and only have 7 hours on it. The machine sat around for 15 months after being manufactured before I bought it. I suspect condensation got in there during that time (the hub cap has gaps allowing air to get behind them). Just to be safe, I'm going to buy two more caps and O-rings, and another set as a spare. Given how vulnerable the caps are, it might be prudent to have a spare in the tool box.