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Discussion Starter · #1 ·
Hello all.
I'm going to be working on a 1997 Polaris Sports man 500 4x4
It runs well. Owner is an 80 year old guy. The things I'm going to tackle are
One front brake caliper is dragging. Either rebuild or replace
Left front CV boot torn. I'm thinking of just replacing the axle assembly.
Going to do full oil service and new air filter and spark plug.
I've never worked on a Polaris before. Any tips like if there's certain
brands of aftermarket parts I should avoid, will be appreciated.

Mad
 

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couple of things - spend the money on the polaris service kit. Engine oil / filter / front and rear diff fluid (2 different kinds) Pick yourself up a set of metric hex drive bits for 3/8 drive socket. Everything is a metric hex. Lastly - a 65mm 14 flute oil filter socket. Changing the filter is a PITA since it is close to the skid plate and behind the battery. A long extension also so you can sneak it by the front tire.
 

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Discussion Starter · #3 ·
Thanks for the info. It was the RH front drive axle. Already have it out. Waiting for parts. The U joint was
absolutely shot. Ready to fail. Lower ball joint pretty bad too. I spoke to the owner and told him that,
to make this thing decent, we basically need to replace everything in the front end. He's 84 and is planning on
riding it at walking speed so he just wants the minimum done. Luckily things look much better on the
left front and rear end. As for the oil and filter, this one has the filter readily accessible on the left side of the motor.

Mad
 
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