2004.5p0laice

hvtexskeeter · #1 (**permalink**) 12-04-2011, 08:58 PM

I recently bought a set of new factory take-off alluminum wheels and tires off of a 2012 Sportsman 850xp orange madness edition to put on my old 2004.5 sportsman 500ho. The bolt pattern is the same but the hubs on my 2004.5 sportsman will not allow the new wheels to sit flush on the hub due to the 4 humps that are cast into the hub. I know I will have to put on longer studs on the hubs do to the thicker alluminum wheel but has anyone every ground off the humps to except a different wheel? Does not look like it will weaken the hub just dont want to have to widden while wheel base with wheel spacers (or spend the $$$$). See the pic below.

thomaseweber · #2 (**permalink**) 12-05-2011, 08:48 PM

Don't look like it would bother anything.

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polman500 · #3 (**permalink**) 12-06-2011, 04:14 AM

I've never noticed that hump before...or its never been an issue for me. From your picks it looks like your studs are chewed up pretty good anyway. You can get extended studs fairly cheap. I'd check on them before you grind and you might should check the difference in offset of your wheels vs. the xp wheels to make sure there are no clearance problems.

hvtexskeeter · #4 (**permalink**) 12-06-2011, 12:32 PM

polman do you know where I can buy extended studs (3/8 24)? I checked Orielys auto parts close to my house and they said that they didnt have it listed by size just by vehicle and they didnt have atv's. I would have to bring in one of the studs and go thru all of thier stock to see if I could find a match.

hvtexskeeter · #5 (**permalink**) 12-06-2011, 05:33 PM

Took another look at the wheel and tire swap and noticed that my itp 589's are slightly rubbing my front tie rod ends just a bit. Guess I need to add wheel spacers anyway. Really dont want to go grinding on the stock hubs to remove the humps either. The only problem now is that the rear of my sporty measures 48" with the 12'wide 589's and the front is 46". The offset on the XP alluminum rims is in fact different as measured today they are about 3/4 inch deeper from the back of the rim to the mouting surface of the hub versus the stock steel rims. So my best guess is the 1 1/2 inch spacers will really only move the tire about 3/4 of an inch out. That and the 489ATII that will be running on the XP rims are alot narrower than the ITP 589's. The only reason that I care about width is that some of the trails that I ride on in New Mexico have a 50" maximum width rule. I plan on running the 489 / XP rims in New Mexico so hopefully it will all work out. I looked at the 1 1/2" wheel spacers on ebay. PAIR 1.5" Wheel Spacers Polaris Sportsman 500 1996-2008 | eBay anyone have any other recommendations? Thanks in advance.

polman500 · #6 (**permalink**) 12-07-2011, 05:05 PM

Just search ebay for "polaris extended studs"

JKOLKA · #7 (**permalink**) 01-02-2012, 08:25 AM

Did you get them installed. What did it take to make them fit. I have same issue.

hvtexskeeter · #8 (**permalink**) 01-02-2012, 09:26 PM

I bought the wheel spacers off of ebay listed above and they were machined to fit around the 4 humps on the polaris hubs and fit perfectly. Only problem is the short studs on the stock polaris hubs will have to be replaced with longer studs so that I can get have proper thread engagement thru the nuts with the thicker wheel spacers. As it is now with the spacers the threads do not even stick thru the nuts. I have always wanted at least 2 threads showing on a bolt as general rule. Still need to find where I can buy longer studs that will fit a polaris hub and havent had really luck searching ebay etc..... If anybody has a supplier let me know. PS the 850XP wheels fit good with the spacers with plenty of clearance / no rubbing and do not stick out past the fenders.

POLARIS13 · #9 (**permalink**) 01-02-2012, 10:23 PM

I tried getting the xp aluminum wheels to fit but they would touch my shocks and something else I believe....they are designed for the xps wheel set up....and for the lug....DON'T TRY orileys, napa, or any place....I did and I even looked in there parts book and the smallest one they sell is 7/16.....mine were siezed up and I snapped one off one time so I looke at the above places.....the best place is the dealer. My dealer had a tub full of them for a buck a piece! Pretty cheap for a POLARIS BOLT/WHEELE STUD. Any questions, ask!