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Old 04-05-2010, 04:09 PM
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2004 sportsman 500 ho questions/concerns "newbiee"

Hey guys! my first time here....love the forums...ok i have a few questions...i just picked up a 2004.5 sportsman 500 ho with 300 hours and 2100 miles on it....now i want to create my own maintenance chart.....so i did the oil change/filter, new spark plug, transmission oil with polaris synthetic gearcase lube. after i did the tranny fluid change i went on to the front gearbox...now in my manual and i bought a clymers manual it says there is a fill plug and a drain plug....all i found was 1 plug on the left bottom of the gearbox... so i opened it and almost dry.....so i put oil in it level with the hole....is this right????

now i went on to the rear gearbox.....where the *** is the plugs for the rear gear box??? i could not find anything......i bought the polaris oil kit for the tranny and front and rear gearboxes and the jugs in it say Demand Drive Plus, ATV Angle Drive Fluid , and the synthetic tranny fluid....where does the angle drive and demand drive fluids go???

so i went on to grease the joints.......oh man....all i found were the 2 grease nips on the bottom of the front struts.....there is none on the u-joints or anytthing anywhere else .....is this normal guys?????

Please help me i have never owned an ATV before and am worried i am not doing the proper maintenance on the machine.....i dont want it to brake b/c of lack of maintenance..

Thanks In advance for your help guys!

Last edited by nicks500HO; 04-05-2010 at 04:17 PM.
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Old 04-05-2010, 06:18 PM
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I believe the rear diff and the tranny is all one piece is it not? also there should be 2 plugs on the front diff.... look really hard. i believe it's in a corner and hard to see.
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Old 04-05-2010, 07:11 PM
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First off, welcome to the board!
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Old 04-06-2010, 04:22 AM
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Quote:
Originally Posted by Bruce! View Post
First off, welcome to the board!
Thanks Bruce
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Old 04-06-2010, 02:09 PM
nicks500HO's Avatar
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Quote:
Originally Posted by 4play View Post
I believe the rear diff and the tranny is all one piece is it not? also there should be 2 plugs on the front diff.... look really hard. i believe it's in a corner and hard to see.
yea i searched and searched for it but could only find this one plug...
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Old 04-06-2010, 03:33 PM
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thats the fill plug
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The Kid
2001 500 H.O. Sportsman "Hoggwaller"
2in. lift,with HD ranger springs up front w/stock axles,2in. in the back
heel clicker
Warn 2500 puller outter
SS108's
29.5's Laws skinny/fat
rubber down custom intake
homemade exhaust snorkel
rad. relocated up top
chains on front & rear A arms
swaybar removed
working on quads for 12 yrs let me know if i can help
"Hold my beer and let me show you how to really f#%* shit up"
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Old 04-06-2010, 05:19 PM
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do you know where the drain plug is?
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Old 04-09-2010, 07:59 AM
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i always go to atvpartcenter.com and look at the microfiche diagrams when i need to find that kinda stuff..
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Old 04-09-2010, 10:58 AM
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awesome looked great thanks chickn
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Old 03-05-2011, 11:13 AM
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do i have to remove the axles on a polaris 500 ho 2001 to repalce the bearings and seals
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