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Discussion Starter #1
Wondering if a 2011 diff will fit the 2008 model. The 11 is a 550 sportsman and the 08 is a 500. Both efi. Anyone know for sure? Found a good deal (I think) on one that has all the parts I need to fix mine.
 

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I presume you are inquiring about the front gearcase?

Probably not, but..............

The front gearcase had ADC from 09 and up

The front gearcase was the same for:
2009 SPORTSMAN XP 550 (A09ZN55AL/AQ/AS/AT/AX) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP 550 INTL (A09ZN55FX) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP 850 (A09ZN85/8X ALL OPTIONS) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP 850 INTL (A09ZN85FL/8CFL) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP EPS 550 (A09ZX55AC/AL/AQ/AS/AX) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP EPS 850 (A09ZX85/8X ALL OPTIONS) - Drive Train, Front Gearcase Internals
2009 SPORTSMAN XP EPS 850 INTL (A09ZX85FS/CFS) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN 550 (A12ZN55AA/AQ/AZ) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN EPS 550 (A12ZN5EAD/EAH/EAL/EAM/EAO/EAT) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN FOREST 550 (A12ZN5EFF) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN FOREST 850 (A12ZN8EFK/EFO) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN TOURING EPS 550 (A12DN5EAF/EAR) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN TOURING EPS 850 (A12DN8EAF/EAH/EAR/EAW) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN X2 550 (A12TN55AA/AZ) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN X2 550 INTL (A12TN55FA) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN XP 850 (A12ZN85AA/AQ/AZ) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN XP EPS 850 (A12ZN8EAD/EAH/EAL/EAM/EAO/EAS/EAT) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN XP TOURING EPS 550 INTL (A12DN5EFR) - Drive Train, Front Gearcase Internals
2012 SPORTSMAN XP TOURING EPS 850 INTL (A12DN8EFW) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN 550 (A13ZN55AA/AQ/AZ) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN 550 EPS (A13ZN5EAD/K/L/T) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN FOREST 550 (A13ZN5EFF) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN FOREST 850 (A13ZN8EFK/EFN) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN TOURING 550 EPS (A13DN5EAF/EAR) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN TOURING 550 EPS INTL (A13DN5EFL) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN TOURING 850 EPS INTL (A13DN8EFW) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN TOURING 850 HO EPS (A13DN8EAF/EAL/EAR) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN X2 550 (A13TN55AA/AZ) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN X2 550 INTL (A13TN55FA) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN XP 550 HD (A13ZN55TA) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN XP 850 (A13ZN85AA/AQ/AZ) - Drive Train, Front Gearcase Internals
2013 SPORTSMAN XP 850 HO EPS (A13ZN8EAD/K/L/T) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN 550 EPS/XP EPS (A14ZN5EAB/C/M/S) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN 850 WV (A14YN8EAJ/EAT) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN FOREST 550 (A14ZN5EFM) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN FOREST 850 (A14ZN8EFP) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN TOURING 550 EPS (A14DN5EAH/EAR) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN TOURING 850 INTL (A14DN8EFQ) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN TOURING EPS 850/HO (A14DN8EAH/EAQ/EAR) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN X2 550 EPS (A14TN5EAA/EAD) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN X2 550 EPS LE UE (A14TN5EAI) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN X2 550 INTL (A14TN55FA) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN XP 550 EPS HD INTL (A14ZN55TA) - Drive Train, Front Gearcase Internals
2014 SPORTSMAN XP EPS 850/HO (A14ZN8EAB/C/I/M/P/S) - Drive Train, Front Gearcase Internals A14zn8eab/I/C/M/P/S

The gearcase for the 08 500 was the same for these models:
2007 SPORTSMAN 500 EFI (A07MH50AB/AL/AQ/AX/AY/AZ/MN50AF/AN/AT/AY) - Gearcase, Front (If Built After 7/17/06) A07mn50af/An/At/Ay (49Atvgearcase1332568)
2007 SPORTSMAN 800 EFI (A07MH76AL/AQ/AX/AY/AZ/A2/MN76AF/AT/AY) - Gearcase, Front (If Built After 7/17/06) Mn76af/At/Ay (49Atvgearcase1332568)
2007 SPORTSMAN X2 500 EFI (A07TH50AL/AQ/AU/AZ/TN50AF/AS/AU) - Gearcase, Front A07tn50af/As/Au (49Atvgearcase1332568)
2007 SPORTSMAN X2 800 EFI (A07TH76AU/TN76AF/AL/AU) - Gearcase, Front A07tn76af/Al/Au (49Atvgearcase1332568)
2008 SPORTSMAN 500 EFI SCANDINAVIAN (A08MH50SS/SQ) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN 500 HO EFI (A08MN50AF/AN/AQ/AR/AS/AT/AW/AX) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN 800 EFI SCANDINAVIAN (A08MH76SS/SF) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN 800 HO EFI (A08MN76AF/AL/AQ/AR/AS/AT/AX) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN TOURING 500 EFI (A08DN50AF/AS/AW/AZ) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN TOURING 500 EFI QUAD (A08DN50EA) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN TOURING 800 EFI (A08DN76AF/AG/AH/AL/AJ/AS) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN TOURING 800 EFI INTL (A08DN76FC) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN X2 500 EFI (A08TN50AT/AX/AZ) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN X2 500 EFI QUAD (A08TN50EA) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN X2 700 EFI (A08TN68AX/AZ) - Drive Train, Front Gearcase & Mounting
2008 SPORTSMAN X2 800 EFI LE (A08TN76AA/AQ) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN 500 EFI (A09MN50AN/AX) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN 500 EFI TRACTOR (A09MN50ET) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN 800 EFI 6X6 (A09CL76AA) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN 800 HO EFI (A09MN76AX/AZ) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN TOURING 500 EFI (A09DN50AB/AZ) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN TOURING 500 EFI QUAD (A09DN50EA) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN TOURING 800 EFI (A09DN76AB/AL/AY) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN TOURING 800 EFI INTL (A09DN76FC) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN X2 500 EFI (A09TN50AX/AZ) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN X2 500 EFI QUAD (A09TN50EA) - Drive Train, Front Gearcase & Mounting
2009 SPORTSMAN X2 800 EFI (A09TN76AL/AX/AZ) - Drive Train, Front Gearcase & Mounting
2011 SPORTSMAN 800 EFI 6X6 (A11CF76AA) - Drive Train, Front Gearcase & Mounting
2011 SPORTSMAN FOREST TRACTOR 500 EFI (A11MN50ET) - Drive Train, Front Gearcase & Mounting
2012 SPORTSMAN 800 EFI 6X6 (A12CF76AA) - Drive Train, Front Gearcase & Mounting
2012 SPORTSMAN FOREST 800 6X6 (A12CF76FF) - Drive Train, Front Gearcase & Mounting
2012 SPORTSMAN FOREST TRACTOR 500 (A12MN50ET/EX) - Drive Train, Front Gearcase & Mounting
2013 SPORTSMAN 800 EFI 6X6 (A13CF76AA) - Drive Train, Front Gearcase & Mounting
2013 SPORTSMAN FOREST 800 6X6 (A13CF76FF) - Drive Train, Front Gearcase & Mounting
2013 SPORTSMAN FOREST TRACTOR 500 (A13MN50ET/EX) - Drive Train, Front Gearcase & Mounting
2014 SPORTSMAN 800 EFI 6X6 (A14CF76AA) - Drive Train, Front Gearcase & Mounting
2014 SPORTSMAN 800 EFI 6X6 FOREST (A14CF76FA) - Drive Train, Front Gearcase & Mounting
2014 SPORTSMAN FOREST TRACTOR 500 (A14MN50EM/EA) - Drive Train, Front Gearcase & Mounting
2015 FOREST 800 6X6 (A15S6A76FA) - Drive Train, Front Gearcase & Mounting

Hope this is accurate and helpful - maybe someone with first hand experience will offer better insight. Example; back in the 70's Kawasaki had a problem with the rear wheel in the first generation of the Z1 900 - in the shop, we looked at a wheel for a H2 750 triple and to our eyes they looked the same. In our zeal to get the 'new' Z1 out of the shop and back on the road, we installed the H2 wheel in the Z1 (part numbers were completely different) - we reported what we had done to Kawasaki - later, a service bulletin was released addressing the problem with the Z1 - later a recall was issued - the wheels were indeed the same design, but the Z1 hub casting had been modified from the H2 casting and was weak under certain conditions - the problem did not result in a catastrophic failure, but the hub could flex and the brake backing plate would contact the outer edge of the hub resulting in noise and abnormal wear. The fix for all Z1's was the installation of the H2 wheel.

The gearcase may indeed fit, but someone with more knowledge needs to comment on this thread.
 

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So there's the ADC in the 550 you would have to contend with. Just leaving it unplugged would do the trick. Other then that you'll have to verify driveshaft yoke fitment. Then there's the axels, I don't think they are the same. Also bolt pattern for mounting. I've never heard of someone doing this swap. So what's wrong with your diff???
 

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Discussion Starter #4
Buy adc do you mean the on demand option on the four wheel drive switch? Cause my 08 has that. And there are 2 sets of wires going to the front dif. One goes to the regular internal magnits and the other looks like it activates a disconnect right where the driveshaft goes in before the pinion.
 

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ADC=Active Decent Control.

Does your handlebar switch look like this:
??
 

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Open your front box, pull out the rubber access cover in the center. Is there a fluid reservoir with a yellow cap with a hose leading to your front diff?

If not you do not have ADC.

Sounds like you do. 3-position switch and two leads coming from the front diff.
 

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Discussion Starter #8
Yes I do have the res. And two sets of leads. I’ll take a photo of it today. I think I do have the adc on this wheeler. But the 4x4 switch is pretty faded so it is hard to see.
 

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What is actually wrong with yours?
 

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Discussion Starter #11
It would just all of a sudden kick into I’m guessing. Active decent going down the road and dame near toss you off over the bars from what I was told by the previous owner until they unplugged the leads. Now I’m wondering if I can just unplug the set that go to the adc part of the diff and keep the 4x4 hooked up and working. I’ll have to try that I guess.
 

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Discussion Starter #12
Ok. So I finally had time to put it on stands and look at the 4 wheel drive. So the front tires will spin but if you put your feet on them they stop. Seems like the magnetic clutch isn’t working. The gears sound fine and once it starts spinning there isn’t any bad noises or anything it just can be stopped really easy. And also there isn’t any light on ,on the dash pod?? Not sure what that all about. Like I said. I checked the wiring and it seems to get 12 bolts to each wire when you engage the 4x4 switch. Does this mean that the Hilliard clutches are bad? Or maybe the magnet? Since for gears sound good should I just rebuild what I have? I have no problem doing the work and I’m not looking for a quick easy way out. But I’d hate to take it all apart just to find out it’s fine inside and it was something electrical or a part that could have been easily changed without taking the dif out. Any thoughts from anyone that knows? Thanks ian
 

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Discussion Starter #13
So I checked it. It spins but if you put your feet on the front tires I can easily stop them from spinning. Also the light isn’t coming on on the dash pod.
 
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