Well I took the plunge tonight and did a complete oil change on the the 500. I thought I would list what I did and what I saw for reference since many of the posts that I read were a big help for me. It all went off without a hitch, no leaks and the dipstick reads "full" after a couple trips around the block (exactly 2 quarts of oil).

Here is what I did and how it went.

1. Started it up and ran it around a bit. Let it idle for a couple of minutes, then into the garage.

2. Pulled the drain plug on the plastic oil tank. First thing I noticed is the oil was pretty bad. Also noticed that the magnet was on the plug in the plastic tank and not on the plug for the crankcase. A good coating of metal "dust" on the magnet. Wiped that all down.

3. Let the plastic tank drain and put the plug back in.

4. Removed the oil filter. Not an easy job, but with a little channel lock persuasion it loosened up. Spun it off and put on the new one...with a light film of new oil on the seal. Cranked it down hand tight (about 1/2 turn past the first stop).

5. Pulled the drain plug from the crankcase. No magnet on this one. That was a pain. Like the manual said, there was about a cup of oil in there maybe a little more. Went all over the bottom skid plate, but I managed to keep it fairly contained. That plug is a PITA to get back in, but I eventually got it.

6. I had read a lot about checking the screen or not. I decided to do it. I removed the two bolts holding the plastic tank on. That gave enough room to get the hoses off the tank. Then it was easy to spin off the fitting and check the screen. I am here to report that I could find nothing in it or on it. Oh well, I guess I am good for a couple more changes. Manual said I could use Loctite or teflon tape. I used the latter and put it all back together. I used a hose clamp and put that on before I bolted the tank in place, it was easier to get on that way. Put in 2 quarts of oil. Started it up, let it run for about 10 sec, and then shut her down. I heard the psssssssssst of air once I let the clamp go and figured I was good to go.

7. Ran it around the block a couple of times and all seemed well. Idling at 1150rpm and no weird noises. I'm going riding sunday, so that will be the real test.

Thanks to all those who gave me advice and help on my previous questions. It gave me the courage to git er done.

 

** just wondering, what "plastic" tank are you talking about

 

The oil tank on newer models is plastic instead of metal. I don't know what year they changed but it was before I got my '06. I can't remember if my '01 was metal or plastic.

 

I don't know as if I'd like the idea of having a "plastic/poly" oil tank, I think I'd change mine out for a magnesium one. I would think one good whack of a branch could damage it and leave you with nothing but headaches or am I way off base on this?

 

<div class="FTQUOTE"><begin quote>Originally posted by: MaineWheeler

I don't know as if I'd like the idea of having a "plastic/poly" oil tank, I think I'd change mine out for a magnesium one. I would think one good whack of a branch could damage it and leave you with nothing but headaches or am I way off base on this?</end quote></div>

I don't think the material used on the tanks is an issue - Some of the HD desiel engines on off road eqipment use poly/fiber oil pans. The poly is proabbly more damage resistant. The only issue I can think of would be over tightning the threads on the drain.

 

My 01 500HO was metal. I like the fact that my new 08 800 doesn't have that tank anymore. I wonder why they went to plastic. To me, I think the metal would almost act as a heatsink and sort of cool the oil.

 

The oil tank is fairly well protected where it sits. I've taken my 500 anywhere and everywhere and never thought about the tank getting hit with something. I'm more concerned with the CV boots taking damage than the oil tank.

 

<div class="FTQUOTE"><begin quote>Originally posted by: chevyman142000

My 01 500HO was metal. I like the fact that my new 08 800 doesn't have that tank anymore. I wonder why they went to plastic. To me, I think the metal would almost act as a heatsink and sort of cool the oil.</end quote></div>

If it cools the oil that would be a major benefit, the only reason why I mentioned getting whacked with a stick is that on my 500 the oil tank is in the front left wheel well and I have on numerous occasions have had sticks come up into the wheel well while stump jumping through old choppings. JMO though.