Jack,

I had the same problem with the drive train zerks. I found that the angle had to be just right to allow the grease to flow. However, some grease gun tips are adjustable, your's may be one of them.

 

I have a 00 SP500 and it does have a grease fitting under the headlight pod behind the wiring. The problem I have with greasing the SP500 is the front driveshaft. I can't get my hose on the universal joint fittings, front or the back because of the angle. I have the smallest tip on my grease gun I can find. Any suggestions ???

 

Polarized,you will see an access hole in the skid plates for both of these fittings.Jack up the quad,front and rear,remove all the tires,turn the driveshaft fittings DOWN towards the access hole in your skid plates.You will have no problem greasing them babys than.Good Luck===BILL

 

I know this post is for the 500, but need help on a 335. I greased mine today and found 24 zerks 14 of them in the rear 3 in the universal joints 1-in the steering post and the rest in the front end. Does anyone know how many the 335 has and did i miss any in the steering post never looked under the pod.

 

Thanks Bill, I'll try that. I knew there had to be a way, I just couldn't figure it out. This forum is the best thing since ATV's.

 

Here are the zerks that I have found on my '98. This list agrees with my Sportsman 335/500 service manual.

2 - L&R front lower ball joints
2 - L&R outer tie rod ends (not greasable on some)
2 - L&R inner part of front control arms
2 - L&R front inner U joints
1 - lower steering post
1 - upper steering post (I have yet to find it!)
1 - u joint at prop shaft leading to front
1 - u joint midway on prop shaft (under recoil)
1 - yoke joint in prop shaft (also under recoil)
1 - foot brake pedal pivot point
6 - L&R rear lower control arms (2 outer, 1 inner)
6 - L&R rear upper control arms (1 outer, 2 inner)
2 - L&R ends of rear anti-roll bar
2 - L&R rear inner u joints ('98 and older only)
2 - L&R rear outer u joints ('98 and older only)

This totals 32 zerks on my '98! The newer '99s and 00's should have 6 less, totalling 26. The newer units do not have greasable outer tie rod ends (less 2 zerks), and they have dual CV joints instead of u joints on the read drive shafts (less 4 zerks).

The inner tie rod ends on the front of my '98 do not have zerks. They have rubber boots that I force grease into with a needle.

Polaris warns that 3 pumps maximum should be used in the prop shaft yoke.

Polaris recomments that the u joints are filled until fresh grease is expelled from all 4 sections of each joint. This way all water and dirt should be expelled.

Greasing is relatively quick once you figure out how to access all of the zerks. As Bill mentioned there are tricks to some of them but you will get the hang of it.

Hope this helps,

DJ

 

Hawk045,

the way I see it you missed 2. One on the foot brake pedal pivot and one at the upper steering pivot.

DJ

 

Thanks for the info.