I have owned 4 new polaris'. I currently own a 04.5 sportsman 500 and a 05 sportsman 500. Here's the problems I have had with the 04.5
1. Kept getting oil in the cover and burnt belts. After several trips to the dealer they found a small casting flaw and replaced my lower half of engine... problem solved.
2. bad engine noise... dealer said its normal but my other atrv's don't make this noise.
3.bearings went out on my fan 200. 00 new fan
4. rear wheel bearings went out... replaced at @ 200.
5. terrible noise coming from the front gear box.. axels are extremely loose and can move them all around with my hand!
6. 1 busted rear boot. fixed
This is normal riding with a few times in the mud. How are you all doing?

Noble

 

both of our polaris's have been very dependable, only thing ive had to replace is a sprocket and belt just w/normal wear..sry to hear of all ur troubles

 

my dad has a '04 400 sportsman with 300+ hours and has no probelms at all besides 1 plugged air filter. i have a '92 250 trail boss that has no probelms at all besides the usual consumable parts. and now i have a '05 500 sportsman and it has not had a single probelm but it only has 20 hours on it. and all 3 of the machines are used every day for irrigating and chasing cattle. so they dont have an easy life. but its to bad to hear your troubles.

 

3000 rough miles, battery, outter tie rod ends, rear bearings, 1 strut.........

 

Do you guys change your front gear oil and tranny oil after riding with some mud holes. I have just over 2,000 miles on my 04.5. I can't afford the upkeep on it anymore!!!! Maybe its time for another brand. My buddies ride the same as I do and never have a problem. Most of them have Yami kodiac's. I love the way polaris' ride but if they can't hold up I'll have no option but to get rid of them.

Noble