[Snowchaser]

Here is the link for the service manual site. Its $5 for all 600 some pages. Everything is there. Digital download. I have bought numerous service manuals from there with no problems. I rebuilt mine front to back and i found that looking for parts is relatively easy. Ebay search for xplorer and trailblazer parts. They are straight axle in the rear. Polaris was smart and they use the same axles and center tensioner as their single axle cousins. Same bearings and seals too. I bought a sprocket kit that came with all 4 sprockets. Bulk roller chain and made my own as i got twice as much chain for the same price as premade lengths. Mine had a blown gear box, which was fun finding parts for that. I put nilight brand off amazon led light pods in place of the factory crap. No bulb out there will make those bright. 2 fog for low beams and 2 spot for high beams with the 3 light mod so all 4 stay on in hi beam. 13 watts per pod x 4 is less than the handlebar pod light alone and you wont need anything else. Led bulbs in the taillights cause i had them. My bed has the saginaw electric actuator to power dump and winch. I run heated grips and thumb warmer and I have not had problems with the stator handling it. A winch is a momentary load plowing too. I added a second battery right behind the first one and an isolator switch for the heck of it. I love mine. That think with maxxis bighorn knockoffs is unstoppable.

2000-2001 Polaris Sportsman 500 6x6 Service Manual

Polaris ranger and atv service manuals.Polaris manuals are downloadable in PDF format.Polaris 2016 Ranger 570Crew/900XP Crew

atv-service-manuals3.mybigcommerce.com

http://

 

[Snowchaser]

auto parts stores sell prestone radiator flush. Looks like a tiny antifreeze jug. Should clean all the gunk out.

look in manual. Should show the different stators and wiring differences. Its the same engine as all the other 500 sportsmans of that era and they don't change much. For $5, buy the sportsman service manual too and look at those stator options. I dont think my stator was that low and its the same year.

 

[Snowchaser]

50 cal ammo can for a glove box and made the back rest a lot higher. Much more comfortable!

 

[Snowchaser]

 

[Snowchaser]

The spacers would make your turning radius larger, which isn’t great to begin with, but thats about it. If you haven’t dealt with sportsmans before, make sure you have the manual and service the front hubs. 4 bearings in each front hub with the hilliard clutch that makes the 4wd. Not hard to disassemble and service at all, but has a particular way of tightening the axle nut while rotating the drivetrain to make sure the bearings are properly tensioned. They take 2.5 oz. Of demand drive fluid or ATF type F. Back when polaris would actually recommend normal fluid equivalents for their outrageously overpriced dealer fluids.

 

[Snowchaser]

When looking for parts compatibility, just remember the front half (motor forward and front drivetrain) is all sportsman, with a trailblazer/xplorer gearbox and rear drivetrain.

 

[Snowchaser]

I would pull your rear wheel hubs and the axle with center hub out of the frame. My biggest corrosion points were there. Aluminum hubs and eccentric bearing carrier onto steel shaft and steel frame is never good. I anti-seized or greased those areas when reassembling. The rear chain should come off the sprockets if both eccentric carriers are rotated towards each other.
Your front hubs shouldn’t require any heat unless maybe a hilliard retainer spring broke. Everything is slip fit in there. 2 tapered rollers in the hub and 2 more behind it in the strut.
I ride snowmobiles in the winter so mine don’t get much use. I would ride it and check plug colors. I would definitely block off the radiator with cardboard when it that cold though.

 

[Snowchaser]

It would be worth the time to split the gearcase if you are confident and inspect/replace the bearings. The case halves are pretty spendy if you can find one at all. The gearing inside is specific to the 6x6 and i could not find replacements. I ended up heating up and straightening one shaft inside. They are very common single row ball bearings. All 4 the same. Get Timken, koyo, skf. Top quality only about $15 a bearing.

 

[Snowchaser]

The secondary clutch has one bolt and should slide off a spline. Nothing under the dome to get it off. The primary clutch is on the tapered crank shaft. Takes an inexpensive but special bolt to pop off. You do not need to remove the primary clutch. The guard behind it should flex out the way enough to get to the mid swing arm pivot bolts. Very large hex if i remember correctly.

 

[Snowchaser]

Aluminum and steel together! Genius! Yeah i beat on mine a bit too. Both rear axles are tapered roller bearings held in by spanner nuts. A few snap rings in there holding other things on the axle too so clean things up with a wire brush to make sure nothings hiding in there holding things up. There are a lot of pieces that all go in order on each axle. Take pictures before you start and lay everything out in order as it comes off and take more pics. My kids like to come by and “help” dad put stuff together and who knows where things end up!