I have a '02 sportsman 500ho that I'm going thru the book and changing all the fluids after a break in period. I'm a little confused because the wonderful "model generic" owners manual seems to indicate that there is a rear gearcase that needs changing and the trans. I can't find a drain bolt for the rear gearcase anywhere and the best I can figure is it's actually tied into the trans, only requiring one fluid at the back to get done. Is this right or am I missing something. Thanks. also has any one counted the grease zerks that need to get done. I came up with 24.

 

The generic owner's manual needs to be supplemented with a little experience in maintaining the Sportsman.

There is no rear differential! Access the drain plug through a hole in the belly pan, just in front of the hitch. Yes, "24" (grease fittings)is correct - including the sterring column fitting under the light pod.

 

Don't you just hate those 'one size fits all' manuals???

The sportsman has no rear gearcase, just a transmission (but it does have a front gearcase).
The Magnum models have a rear gearcase. If you compare them to the Sportsman's you will see that it has 2 seperate gear housings in the rear, whereas the Sportsman has only one.

 

Wish my 2003 Sportsman had 24 grease zerks, I believe I have only 5 or 6. What a bad idea to change to this.

 

there all CV joints, permentantly closed. my 800 only has 3