I have a 2002 Sportsman 500 HO. The bike has always been kept in good condition, never rolled, etc. The plastic is starting to shift. This problem happened about 3 years after I bought it.(It was bought brand new). What is happening is the plastic is shifting to the right. Bad enough that the side access panels don't fit together any more, but the seat doesn't snap into place easily, the gas cap almost digs into the plastic when you put it on tight, the fuel **** doesn't fit into the factory hole made in the plastic, and the front fenders are staring to get humps in them.
Any info or comments you guy have would be greatly appreciated.

thanks,
Tony

 

did you check where the plastic bolts to the frame to make sure nothing has loosened up or a brace isnt out of wack. been a couple of yrs since my 500 but dont remeber any such problems.

 

I checked all the bolts and everything seems to be tight. Everything is attached like it should be.

 

Strange, and after riding this weekend, and spent yesterday with
"clean up" duties, I noticed that my PLASTIC under the seat where
its attached to the frame next to the air box is NOW completely
severed (cracked off VS hair crack in which is commonly reported
by many Polaris riders). Another plastic thing I am noticing and it
just maybe me, but after I wash and really scrub with soapy water
etc. is a faint brown staining effect that won't come out with re-washing
and re-scrubing?

Could the mud and dirt be staining my plastic. FYI, I keep my quads covered
and out of the SUN, and pretty good care if I must say so.

R'

 

For whats its worth,on some models,spacing up floorboard can help close gaps on panels.