I have to replace the oil pump on my 96' Sportsman 500. What years are interchangable if any? Thank you for your info.

Jeff

 

1996 to 2002 models show the same #3084944 for the pump assembly. 2003 model and up changes to a different part number,but the inner and outer rotors,etc show to be the same as the old pump number. #3084944 is for a complete pump including rotors,strainer, pump housing, pump shaft,etc. Depending on your needs the main wear items on the pump are the inner and outer rotors that pump the oil. OPT

 

Thank you very much. That is exactly what I needed to know. I am going to replace all of the bearings in there while I am at it. The cam looked great, should I replace that also? It has 2500 miles on it. Or I could get in nitrided, a form of heat treating, to be sure that it is hard enough.

Jeff

 

Best to mic the cam journals and the intake and exhaust lobes first! Magneto and Clutch side journals should be between 1.4935-1.4941. Exhaust and intake lobes std is 1.2884, maximum limit is 1.2766. If less than these measurements replace the cam! This is the first year of the soft cams (1996-2000 models)
If with in tolerance, heat treatment is your call! I just replaced flattened cams that customers brought in to me with the updated stronger ones! See what the cost is and if there is any warranty on the treatment! I finally have a pdf manual on this! You don't think I could really remember all this do ya?? OPT

 

My motto "If it ain't broken don't fix it" our 97 500 sportsman run fine with 7500 miles on it with its original cam. I checked my cam and it looks fine with 3600 miles on it.