Polaris Sportsman 500 Transmission Removal/ Replace and Inspection!

Рет қаралды 19,416

Titaniumman Garage

3 жыл бұрын

I'll show you in detail how to remove a Transmission and see what's going on inside and replace it.

Пікірлер: 63

@ljf241 3 жыл бұрын

Great vid! Awesome work! Best of luck! Merry Christmas!

@TitaniummanGarage 3 жыл бұрын

Thanks. Have a Merry Christmas as well.

@Broadley1980 3 жыл бұрын

Great video, would love to see you pull the gears out especially the silent chain gear that is commonly stripped out.👍

@TitaniummanGarage 3 жыл бұрын

That's a great idea for a video. I'll have to buy some parts for it.

@mikelane4940 3 жыл бұрын

Great videos , refreshing my memory from years ago . Now getting back into it with the kids , I just got a 06 450 sportsman and the speedometer just started oscillating back an forth ,any ideas why

@moneyhauler1 3 жыл бұрын

Hey. Great video. I recently purchased a 1999 sportsman. One of the rear axles wobbles in the trans case. I believe the carrier bearing is pooched. Do I have to remove the transmission to replace it?

@G3MsFixIt 2 жыл бұрын

Good video i hope its similar when i take the 2005 Polaris ATP 500 4x4 apart that will help alot - but i have alot better idea of what im getting into - thanks.

@chadmorris9940 2 жыл бұрын

Hello, did you ever get the rebuild kit for your old gearbox. I’m trying to find it online

@chrisg6473 3 жыл бұрын

I wonder why they moved away from that type of rear braking system? Seems like a better system than your typical singular rear caliper one a tire.

@bradhawks5014 Жыл бұрын

I am to the point of putting transmission back together. Anyone know what kind of sealant I should use to put the two transmission sides back together?

@michaelmarcucci3980 3 жыл бұрын

Love your videos I watched the one that you made a 500 out of the 425 just wondering what about a 400 into a 500? Keep the videos coming. thanks, Mike

@TitaniummanGarage 3 жыл бұрын

I had heard the 400 connecting rod was a bit shorter.

@michaelmarcucci3980 3 жыл бұрын

@@TitaniummanGarage you would have to change the connecting rod, piston and jug. Would the head and the cam be the same?

@TitaniummanGarage 3 жыл бұрын

@@michaelmarcucci3980 I believe they are. I would have to double check.

@bobdole7886 2 жыл бұрын

Nice video, a friend of mine suggested you. I'm wondering how much te would estimate for this swap on a fully assembled machine, (time including removing and reinstalling plastic)?

@TitaniummanGarage 2 жыл бұрын

I took my time. Even painted the rusty frame. I did this in 2 days. 4 hours each day. For a person that has done this job a couple times I would guess 4 to 6 hours.

@simeonc.4909 Жыл бұрын

I have a 2000 sportsman 500 and the differential is locked on it so it binds around corners. What do you think the issue might be?

@TitaniummanGarage Жыл бұрын

I would check the hub bearings to see if the 4x4 is not disengaging. Sometimes the bearings rust or the hillard clutch breaks inside the hub making act like it's in 4x4 all the time making it steer hard.

@jandeband 8 ай бұрын

My 99 polaris 500, all of a sudden has no forward or reverse, when i move selector it moves freely, something came loose or broke inside the gear case, happened all of a sudden, anyone know what happened ?

@rossweaver2128 7 ай бұрын

Any tips for severely seized front driveshaft? I’ve beat the hell out of it.

@TitaniummanGarage 7 ай бұрын

Do you mean front axle shaft? I had one seized so bad. I used a air hammer to get it out and lots of PB blaster.

@stevenstrout2393 2 жыл бұрын

Do you have a video on a sportsman 500 year 2005 on fixing transmission .such as not going into hi gear.

@TitaniummanGarage 2 жыл бұрын

No. I haven't done that year yet. My 700 video should be similar.

@GSLBoling1979 3 жыл бұрын

Titaniumman, quick question..... I picked up an 01 Polaris 500, but the frame is swiss cheese. I have a couple 97 400's though. Think I could put the 500 set up in the 400 frame? Thanks

@TitaniummanGarage 3 жыл бұрын

I have pondered that myself. The problem is the engine mount locations. If you have a welder maybe.

@GSLBoling1979 3 жыл бұрын

@@TitaniummanGarage so I just rebuilt my 97 400. Water pump bearing and seals all the way back out. Now I'm getting pressure in the coolant system when I try to start it.....? It did start and run for a few minutes last night. Now nothing.... Any ideas? I've got fire, fuel, and air. Thing should be running. Compression is about 90. I know it's lower then I would like, but it should still run.

@TitaniummanGarage 3 жыл бұрын

Check the spark plug. See if it's wet. Could be a head gasket.

@WmiuskUSA Жыл бұрын

I was driving around and then all of a sudden it wouldn’t move in forward or reverse but the engine kept running and reving like normal. I checked the cvt belt and it is good. When i have it on jack stands and rev it up high the wheels will spin (not spinning full speed) but when the wheels are on the ground they wont. Its a 2006 Polaris Hawkeye 4x4

@TitaniummanGarage Жыл бұрын

It sounds like a possible clutch issue. Try pulling the belt off and rev the engine. see if the primary clutch moves in and out as you feather the throttle.

@jasonjohns1624 3 жыл бұрын

I'm about to replace my transmission did you take the clutches off all the way or just tske the bolt out

@TitaniummanGarage 3 жыл бұрын

I had a tough time getting the primary off so I left it on and just took secondary off and flexed backing plate to remove tranny. If you can get both off it easier.

@jasonjohns1624 3 жыл бұрын

Awsome thank you for the advice

@daveh2612 5 ай бұрын

I have a 2008 Sportsman 500 and the u-joint that connects to the front output shaft/yoke you show at 13:35 has REALLY excessive play. I haven't pulled the prop shaft out yet to inspect, but if the transmission output shaft splines are shot, how bad of a repair is that? Better to just swap a whole used transmission or does that shaft come out easily??

@TitaniummanGarage 5 ай бұрын

you can remove the shaft from the transmission to the prop shaft( shaft going to front differential) pull the 6 or 8 bolts and it should come right out. you might have to remove a bolt or 2 and pry up on transmission.

@TitaniummanGarage 5 ай бұрын

Oh wait. sorry. I was thinking of a 6x6 transmission. I doubt the splines are bad. but if so you might have to pull tranny.

@daveh2612 5 ай бұрын

@@TitaniummanGarage I noticed that the prop shaft has a regular nut and bolt through the hole where it meets the front differential instead of a pin so it’s been changed before and I wonder if it’s a garbage aftermarket shaft that has worn splines at the transmission side.

@TitaniummanGarage 5 ай бұрын

@@daveh2612 Yikes. That a bad repair. That bolt could break. I would pull the prop shaft. Inspect the u joint and splines. If it looks good put a roll pin back in.

@daveh2612 5 ай бұрын

@@TitaniummanGarage OK will do, I appreciate all of your knowledge on this channel, I’m in southern Wisconsin, but if I was a little bit closer, I would just bring this thing to you lol

@judypayne698 Жыл бұрын

I need information on my snowmobile 500

@guybrick4490 3 жыл бұрын

Hi I talked to you The other day about the Bendix possibly rattling on my 94 400 Polaris Do you happen to remember if that Bendix will come out of there without removing the Engine starter Fly wheel gear? I have not been able to get it out at any angle yet.

@TitaniummanGarage 3 жыл бұрын

Yeah. Flywheel has to be removed. I don't think you can get bendix all the way out otherwise

@guybrick4490 3 жыл бұрын

@@TitaniummanGarage Thank you for your fast reply I was just now underneath trying to remove the starter thinking that would help Looks like I’m off to Harbor freight to buy a puller

@guybrick4490 3 жыл бұрын

Just giving you a follow up I did get the new Bendix installed. And the rattling noise is gone!! When we talked the other day you had mentioned a Bendix shim/washer, I sure am glad you told me about that because I would have overlooked that, It was stuck tight to the old Bendix I actually had to pry it off. Anyways I honestly appreciate your help and I saw in one of your videos you mentioned that you live in WI. If you ever get near Eau Claire give me a shout I always have plenty of beer in my garage I just can’t get the temperature up past 45° this time of year LOL 😂

@TitaniummanGarage 3 жыл бұрын

I'll keep that in mind if I'm out that way. I'm 60 miles south of Greenbay on the lakeshore. Glad to help.

@jeirenwilcox3269 3 жыл бұрын

I picked up a 98 sportsman 500 when i got it somtimes it would grind a little bit then stop while excelerating. But today i was beatin it around the yard and it just started grinding realy bad and barely wants to move withouy grinding bad. Is that an easy fix or should i find a new trans for it? Thanks

@TitaniummanGarage 3 жыл бұрын

It could be the carrier bearing. That would be easy. I can't say for sure without cracking it open to see what's going on

@jeirenwilcox3269 3 жыл бұрын

@@TitaniummanGarage thanks and i forgot to mention, that now it has a hard time to go into reverse.

@TitaniummanGarage 3 жыл бұрын

Got it! It's the dog gear. Try adjusting shifter first.

@jeirenwilcox3269 3 жыл бұрын

@@TitaniummanGarage thanks i will try to

@offthestreetsandinthecreek7294 Жыл бұрын

Is this the same transmission that’s in the 99 ranger 500 6x6 ?

@TitaniummanGarage Жыл бұрын

I'm not positive but a friend of mine said they were the same or similar

@offthestreetsandinthecreek7294 Жыл бұрын

@@TitaniummanGarage thank you sir Merry Christmas

@rabalos21 11 ай бұрын

Hey I have exact same issue in mine. Where did you find a replacement tranny? If you rebuild the one you took off I’d gladly buy it off you.

@TitaniummanGarage 11 ай бұрын

I didn't rebuild it. I have 2 more. What state do you live in? What year Sportsman?

@rabalos21 11 ай бұрын

@@TitaniummanGarage Im in Texas. Its a 97. I looked at again yesterday and the reverse light doesnt turn on when i shift into reverse. Im wondering now if its an electrical issue and not the tranny.

@guybrick4490 3 жыл бұрын

Hi Back with another question LOL OK so with the new Bendix it got rid of the rattle and I just removed the starter and Bendix again started it with the pull rope like you said and I still have a strange noise. ( unless this is the normal sound of a 2-stroke ) ? Engine runs beautiful tons of compression I did put the starter back in because if I pull start it again there’s a good chance of breaking my arm LOL Anyways I just uploaded a video could you please take a minute and watch the video listen closely see if you hear anything strange? Link below 94 Polaris noise kzfaq.info/get/bejne/ntN9i7NkudbXYnU.html

@TitaniummanGarage 3 жыл бұрын

I see what you mean. There is some normal 2 stroke noises with older one's sometimes its piston slap. but yours..on the pull start side sounds like something is grinding, like teeth rubbing. Is there fluid in the counterbalancer? You said it didn't make noise with bendix out right?

@TitaniummanGarage 3 жыл бұрын

This is how it should sound. Some 2 stroke noise. Its hard to hear in this video. Check it out.kzfaq.info/get/bejne/ftaDqNh9mpPRp5c.html

@guybrick4490 3 жыл бұрын

@@TitaniummanGarage With the Bendix out it still makes this noise that you are hearing right now I only eliminated a rattling noise with the new Bendix I even put a stethoscope on the engine and the engine sounds smooth inside I also made sure the exhaust system is not rubbing nothing To me it sounds like it’s coming from inside the recoil cover but when I had it off a little while ago I even checked the recoil studied the fly wheel good could not see any problems

@guybrick4490 3 жыл бұрын

Forgot to answer your question yes the counter balance oil is full I changed it two months ago when I bought this machine

@guybrick4490 3 жыл бұрын

Tomorrow I am going to be replacing the read valves just because it’s 26 years old I have not removed that yet to even look at them When I have that read valve cage off should I move the piston around with my hands or something?