Category Archives: Polaris Sportsman

Changing out front lower boot with some questions

’11 Grizz 700 here and I ordered Yamaha front lower boot replacement kit 28P-2510G-00 which consisted of 5 parts. The 4 parts pictured plus a plastic bottle of grease…

First time doing this and the videos I’ve seen entail removing the entire axle then removing the top boot to get at the lower boot. Now when putting back together the top boot area (even though the boot isn’t being replaced) it’s suggested not to reuse the old axle retaining ring but to only use a new ring. So, seeing as how the kit I ordered did not come with the 2 (I believe) retaining rings for the top part of the axle or a second bottle of grease for the top boot it looks like I’ll need to order some more parts before I can start on this one. Whadda y’all think?

Looks like I have all the parts (B, C, D, E) I’ll need for the lower section…

So now I need to get the parts (G, H, I, J, K) for doing the top part…

Also, from what I’ve seen I think I’ll be needing part 26 as well, which I think is an axle retaining clip. So, should I get this part too?

So now on to these clips that came in the kit…

I’ve seen how other clips work but not entirely sure about this one. The only retaining barb I can tell that’s on this clip is the little one in the yellow circle. Other clips I’ve seen have much larger retaining nubs about the size of the ones with the blue arrows. So I’m guessing for this clip you use pliers to squeeze the blue arrow nubs together then hook using the small nub in yellow?

And lastly some questions on getting the 27mm axle nut off. I’ve seen this done with a pneumatic impact gun on a video but I don’t like using those things. One way I’ve seen it described is to jack up and take the wheel off, remove the center plastic cap, replace the wheel and lower to the ground for some traction. Put the machine in park and chock the wheels, then put your wrench on the nut with possibly a breaker ‘cheater’ bar and crank. Same procedure for putting it on except you would prob use a torque wrench. Does this wound like the best way to get this 27mm axle nut off without using an impact gun? Even though the wheels would be chocked I imagine the gears (in park) would take the brunt of resisting the torque on the nut when it’s being forced off. Would this be too much force on the gears?

Crap I know this is a long post already so sorry bout that. I’ll just finish with summarizing my questions which have prob gotten lost in all that writing…

1) Should I order the full second upper boot kit plus the axle
retaining clip part # 26?
2) How to use the retaining clips in the kit I got
3) Best way to get the 27mm axle nut off.

Thanks for hanging in there with me through all that

DIY Lock and ride.

Well here it is, this is for the most part the same as whats on the other forums, only difference is the rubber material. Due to the cost and availability of things in Canada making them the same as the others would cost about $20 a plug, do to the cost of the test plugs. 1. I used a 5/16 eyebolt with nut, going through a #5.5 bung (used for homebrewing/airlock), with a 5/16 t nut with the spikes cut short. 2. Put bung with attached tnut through hole first, decided to place a 5/16 washer and fender washer over top to ensure it had a solid surface to push up against. 3. Shows eye bolts mounted, used fender washers on the seat side as well, remembered about lock washers on the last one, will put them on the the others eventually. 4. Shows how the bottom of the bung mushroomed out nicely.

I’ve had it out for a couple rides one with and one without rider and had no movement. That being said I take no responsibility for your lost seats and or passengers. Total cost was less than $4Can per mount, Cheers guys.

Attached Thumbnails

Click image for larger version

Name:	DSC_0083.JPG
Views:	N/A
Size:	4.05 MB
ID:	26307
 

Click image for larger version

Name:	DSC_0093.JPG
Views:	N/A
Size:	4.66 MB
ID:	26308
 

Click image for larger version

Name:	DSC_0094.JPG
Views:	N/A
Size:	3.95 MB
ID:	26309
 

Click image for larger version

Name:	DSC_0096.JPG
Views:	N/A
Size:	3.00 MB
ID:	26310
 

oil change problem

A friend of mine has a 2008 sportsman 500 efi X2. He is trying to do an engine oil change. When he pinched the line it built pressure in about fifteen seconds and blew a hole in the line. When he took the line off there was no slit in it. Bought a new line, put a slit in it and pinched it off above the slit and oil sprayed out the slot in five seconds. Is there an engine vent that could be plugged?

oil change problem

A friend of mine has a 2008 sportsman 500 efi X2. He is trying to do an engine oil change. When he pinched the line it built pressure in about fifteen seconds and blew a hole in the line. When he took the line off there was no slit in it. Bought a new line, put a slit in it and pinched it off above the slit and oil sprayed out the slot in five seconds. Is there an engine vent that could be plugged?

How do you secure your machine?

For the time being I’m gonna have to let the old 4×4 set out back next to my garage. But I’m not too happy with it just sitting out in the open and am wondering what would be a good way to deter thieves. First it’ll be covered of course from top to bottom. Second I guess I’ll be digging big a** hole and filling it with probably around 500lbs of concrete with a giant 1" diameter loop of rod sticking out the top. It’ll actually be a huge U-bolt clamp I’ll get from a local fastener company. Using this I’ll try to physically secure it looping some hardened chain through what part of the atv I don’t know.

Only other idea (which is a bit far fetched I’ll admit) is to hook up some kind of alarm system by way of a cable like you see sometimes on store merchandise out for display. I assume it would be hooked up to a loud speaker. Again I know this one is going somewhat overboard but considering how easily the quad could be jacked it might be the one deterrent that keeps it safe.

Open to your suggestions

PS. Don’t really live in a bad neighborhood but the neighborhood kids are through my back yard all the time especially at night…thus the need for security.

X2 transmission ,,FUBAR

I lost ,without any noise ,low range and have a knocking noise when in reverse.:hmmm::motz:
High range is ok ,4×4 and ADC is Ok. neutral OK ,turf gard and Park ok.:werd:

Anyone have any experience with the guts of these tranny’s?:flowers1:

X2 transmission ,,FUBAR

I lost ,without any noise ,low range and have a knocking noise when in reverse.:hmmm::motz:
High range is ok ,4×4 and ADC is Ok. neutral OK ,turf gard and Park ok.:werd:

Anyone have any experience with the guts of these tranny’s?:flowers1: