500 sportsman 500 rebuild
 

After a wee accident last year I'm now rebuilding my sportsman onto a new frame.

I've spotted a couple of changes I'll make whilst doing it, but is there anything else that Polaris didn't get right that I can rectify whilst it's all in bits.

A couple of hoses have almost rubber through against edges of the frame I've noticed.

What else should I look at that has caused problems for you in the past?

James

What year 500? With my 2000 sp 500 the lower rad hose rubs on the frame. I used a piece of EPDM and splice adhesive to thicken the hose where it rubs. Then wrapped it in wire loom.

2010, they must of thought about that one as there is convoluted tubing around the hose now. Same with the RHS fuel pipe under the seat.

James

Lot of hoses wore against the frame tube before Polaris fixed that problem. They generally addressed most needed improvements over the years,some small,some large,but if mine I'd install a recoil system for a back up.They started cutting corners on this and really good to have one.Doesn't have to be the more expensive oem recoil assy as knock off replacements are available now. Doesn't have Polaris etched into the cover,but the guts look the same.$120,about $100 cheaper than the oem recoil assy. http://www.ebay.com/itm/NEW-POLARIS-COMPLETE-RECOIL-STARTER-PULL-START-ASSEMBLY-SPORTSMAN-500-1996-2011-/151602690507?pt=Motors_ATV_Parts_Accessories&hash=item234c3979cb&vxp=mtr

I now have a battery jump booster, capable of starting the bike 50 times or so. It's 6"x4"X1" and fits in my pocket if need be.
I've been caught out before whilst winching continuously.

I'm changing all I can to LED to save on amp draw also, so would be interested to hear of any aftermarket lights or Polaris LEDs.

James