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Discussion Starter #1
The tie rod ends are the same part number for the 2004 and 2005 Sportsman. Does anyone know what the difference is with the tie rod itself? Is it longer/shorter? The 04 is p/n 5020926 and 05 is p/n 2134242.
 

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If you're talking about the 500 Sportsman, the newer 2005 model tie rods are about 1/2"-3/4" longer because the newer Sportsman has different struts/springs and more front suspension travel among other changes.
The 2004 is 6.7"/170mm while the 2005 is 8.2"/208mm of front suspension travel.
 

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Discussion Starter #3
If you're talking about the 500 Sportsman, the newer 2005 model tie rods are about 1/2"-3/4" longer because the newer Sportsman has different struts/springs and more front suspension travel among other changes.
The 2004 is 6.7"/170mm while the 2005 is 8.2"/208mm of front suspension travel.
I was talking about the one in my sig. 2004 600. Would that be the same?
 

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Discussion Starter #6
If you're talking about the 500 Sportsman, the newer 2005 model tie rods are about 1/2"-3/4" longer because the newer Sportsman has different struts/springs and more front suspension travel among other changes.
The 2004 is 6.7"/170mm while the 2005 is 8.2"/208mm of front suspension travel.
Do you think the longer 05 tie rods would work ok on the 04 or would they be too long? The reason I ask is I got a deal on the All balls 52-1038 upgrade kit. $40. I wanted to install new ends and I figured I couldn't go wrong for $40. It should be at my house tomorrow.
 

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Since you already have them coming I'd give them a try. Longer should be ok. Its when they're too short that you really have a problem since you can't adjust out far enough to get the tow out right without running out of threads.
 

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Discussion Starter #8
Since you already have them coming I'd give them a try. Longer should be ok. Its when they're too short that you really have a problem since you can't adjust out far enough to get the tow out right without running out of threads.
That was my thoughts too. I guess I'll see this weekend. I guess worse case scenario, I could cut a few threads off... Hopefully it wouldn't come to that. Thanks.
 

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Discussion Starter #9
So much for that idea. Amazon screwed me. Cancelled the order on the day I was expecting to receive it. No notice, just canx.
 
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