Quantcast
Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

xrocket21

2001 Polaris Scrambler 500 4x4 2001, new owner, lotsa questions

Recommended Posts

I bought a used 2001 Scrambler 500 4x4, and it needs some work

-needs front CV joints. Should I replace just the CV's, the whole axle, etc?

I found these:

Polaris ATV Front Axle with Dual CV Joints - Sportsman / Explorer / Scrambler

$170 for one that adds a CV to the inner

or these that are more like stock with a u-joint in the middle:

$200

1999-2009 POLARIS SCRAMBLER 500 4X4 Left Front Complete Axle

-Are the front axles the same left and right?

-in 2001, there were two different models, AA and AB, I dont know which I have, what was the difference?

-The wire going to the AWD sensor on the right front is mangled, I assume its a simple 2 wire setup I can just solder in a new piece?

-It was overheating a bit, im guessing the front fan isnt working, think that would cause it?

-I read that I can use ATF type F in the front diff, is this correct?

-Only one brake lever? Is the hand lever supposed to do front and rear braking and the foot lever just does the rear? Foot lever doesn't work, hoping it just needs to be bled.

I plan to clean the chain, bleed the brakes, add coolant, and change the front diff fluid and oil, any other suggestions?

Share this post


Link to post
Share on other sites


I would start by purchasing a repair manual. It will have alot of the information you seek. As far as rebuilding vs replacing cv joints, that is really a matter of preference. It is more work to rebuild them, so if the money you save is worth it to you, and you have the skills, then rebuilding is just as good IMO. Although, I do like the idea of replacing a u-joint with a cv joint, as long as they are of good quality, I believe that cv joints are better than u-joints.

Overheating, can be caused by alot of things, try wiring the fan to a switch to see if it works and if it helps. It could also be caused by the machine running too lean. That could be caused by a dirty carb, or improper jetting.

Many machines use a foot pedal for the rear and a hand lever for the front brake. I don't know how your machine works, but on most machines where the hand lever controls both front and rear, there will be two cables coming from the handle and the brakes will be mechanical, not hydraulic.

As far as your other questions, I have no idea, hopefully someone who owns one will chime in with some more info. Other than that, like I said, a repair manual could be your best friend.

Share this post


Link to post
Share on other sites


Well, I started breaking into it last night, unfortunately my list of things I completed was smaller than the list of things I found out it needed.

Completed:

-oil/filter change

-hit up grease fittings

-front tires removed and dropped from the 12 psi they had down to 4 psi

I had hoped to get the CV joints out to be replaced, but I can't get the lower balljoint to separate, and I dont have a pickle fork.

I found out the hillard clutches are toast. passenger side was TOAST/EXPLODED, drivers side was just toast.

Found a pair of used ones on ebay, so thats good.

Looks like they just completely neglected the hub fluid.

Now I need to find the 2 dust seals. Any suggestions to find these?

Also, where is the FILL for the transmission?

fun fun fun, this thing is gonna have a lot of new parts by the time I'm done!

new stuff:

-chain

-belt

-front and rear brake pads

-brake fluid

-top off coolant

-engine oil and filter

-grease

-2 front axles/cv joints

-other fluids

Share this post


Link to post
Share on other sites

Hey Xrocket, I had a 99' 400 and my niece has about the same quad as you,

You can try bikebandit.com or The Polaris web site has a parts breakdown if you set up an account,

2001 Polaris SCRAMBLER 500 4X4 (A01BG50(AA)(AB)) OEM Parts, 2001 Polaris SCRAMBLER 500 4X4 (A01BG50(AA)(AB)) OEM ATV Parts - BikeBandit.com

Also, the transfer case fill should be between the foot rest and the frame, I found it easier to remove the right side footrest (for filling), and you can get to the grease zerks on the drive shaft.

I have used ATF fluid in the front hubs, a little cheaper than the polaris hub fluid, ( I had small leaks )

I think the front transfer case uses gear lube

My rear foot brake worked good, but my Trailboss needs to be bled about twice a year

Share this post


Link to post
Share on other sites

Pickle forks ruin dust seals on ball joints. A few raps on the side of the spindle should drop the ball joint out. If that doesn't work, there are ball joint separator tools that you can buy or rent.

Check out this site for parts. Babbitts Sports Center | Arctic Cat OEM Parts | Can-Am (Bombardier) OEM Parts | Honda OEM Parts | Kawasaki OEM Parts | Polaris OEM Parts | Sea-Doo OEM Parts | Ski-Doo OEM Parts | Suzuki OEM Parts | Yamaha OEM Parts

Share this post


Link to post
Share on other sites


Picked it up quite cheap, needs a bit of work.

I would prefer something like a honda 400ex or a 450r, but I mostly ride with people with grizzlies, so something thats 4x4 is really needed. This wheeler is a good compromise.

Here it is before I took a mothers powerball and some polishing compound to the plastics. Got dark so no afters unfortunately.

IMG_0222.JPG

IMG_0223.JPG

It needs front CV joints, so tha was the first project.

IMG_0224.JPG

Having trouble popping the ball joint, so getting a ball joint removal tool at lunch today.

IMG_0225.JPG

Always have my assistant handy

IMG_0226.JPG

Here is the sad state now, with the CV half out. Also, when I pulled the hub off, the drive clutches in the hubs for the AWD are toast, so a used set of those are in the mail.

IMG_0227.JPG

I was changing all the fluids, and the front diff needs 4 OZ to fill it. No dipstick, it just needs 4 OZ. Only thing I could think of was a measuring cup.

IMG_0228.JPG

This small hole WAY down here is where it needs to go. I dont have a small funnel, so I set up my large funnel to a hose, which necked down to a smaller hose to fit in the hole.

IMG_0230.JPG

Here it is set up to funnell!

IMG_0232.JPG

it worked!!!

IMG_0234.JPG

So far I have done:

-new belt

-new gearbox oil

-engine oil

-engine oil filter

-greased about 10 grease fittings

-new rear brake pads

-new grips

-new front diff oil

-dropped the tire pressure from the 12 that was in them to 4 front, 3 rear

Still left to do I have:

-pop ball joints and remove old axles, then install new axles

-heat up the hubs, remove old seals, install new seals

-install new front clutches, reassemble hubs with new hub fluid

-new front brake pads, bleed brakes

-install new chain

Hopefully this will be the last driveway project :hs:

-

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By Hondasher
      I have a 2004 Polaris Trail Boss 330 and I want to eventually fix it up if possible, but the thing is the transmission or Gearbox that allows you to shift into forward and reverse and such isn't connect to the engine at all, it isn't even bolted into the frame. Anyways the Secondary Driven clutch is missing. The ignition was busted so I switched it out and tried to hook up power to it and the lights wouldn't light up and it wouldn't try to let me start it with the electric starter. 
       
      So I bridged the connectors on the starter solenoid and it cranks the motor. I was wondering if anyone knew why the dash lights don't work or any of the buttons. I did find a cable disconnected I have a picture of maybe someone can tell me what it's supposed to be connected to. It has 3 wires going to the connect Green Purple Red. I'll enclose a picture of it and where it is connected on the wiring harness. 
       


    • By Johnnyhorsepower
      I finally found an awsome app for your phone that shows you on a map all the trails near your location. You can read or add reviews, look at picts...etc
      Its called: atv escape

      John
    • By David Miller
      Does anyone know how to access the check engine codes on a 2018 450 sportsman. Just changed battery and spark plug . It runs fine but the light is on and I need this to plow snow and need it reliable. Any ideas . Thanks
    • By colin james
      2012-2014 Sportsman 400/500 factory service manual
      View File This is the factory service manual for multiple models of the years 2012-2014  sortsman 400/500 including hd edition's.
      Submitter colin james Submitted 08/13/2019 Category Polaris ATV  
    • By oxidized_black
      these are what i have in my collection ... always looking for more
      1985 - 1995 Polaris All Models Service Manual
      1996 - 1998 Polaris All Models Service Manual
      1996 - 2003 Polaris Sportsman & Xplorer 500 Service Manual
      1996 - 2003 Sportsman 400 & 500 ~ Xplorer 500 Service Manual
      1999 - 2000 Polaris All Models Service Manual
      2001 Polaris 90 Service Manual
      2001 Polaris Scrambler 50 ~ 90 Sportsman Service Manual
      2001 Polaris Sportsman 500HO Parts Manual
      2001 Polaris Sportsman 500 Parts Manual
      2002 - 2003 Polaris Sportsman 600 & 700 Servive Manual
      2002 Polaris Sportsman 700 Service Manual
      2003 - 2005 Polaris Magnum 330 Service Manual
      2003 Polaris Predator 500 Service Manual
      2003 Polaris Predator Parts Manual
      2003 Polaris Trail Blazer 250 Service Manual
      2003 Polaris Trail Boss 330 Service Manual Part I
      2003 Polaris Trail Boss 330 Service Manual Part II
      2003 Polaris Trail Boss 330 Service Manual Part III
      2004 Polaris Predator 500 Owner's Manual
      2004 Polaris Sportsman Owner's Manual
      2005 Polaris 400 & 500 Sportsman Service Manual
      2005 Polaris 700EFI Owner's Manual
      2005 Polaris 800EFI Owner's Manual
      2005 Polaris Sportsman 400 Parts Manual
      2005 Polaris Sportsman 500 Parts Manual
      2005 Polaris Sportsman 6x6 Owner's Manual
      2005 Polaris Sportsman 700EFI & 800EFI Service Manual
      2005 Polaris Sportsman 800 Twin EFI Parts Manual
      2006 - 2007 Polaris Outlaw 500 Service Manual
      2007 Polaris 700 800 800x2 EFI Service Manual
      2007 Polaris Ranger 700EFI 6x6 Parts Manual2007 Polaris Ranger 700 4x4 & 6x6 Service Manual
      2007 Polaris Ranger XP 4x4 Service Manual
      2007 Polaris Sportsman 450 & 500EFI - 500X2EFI Service Manual
      2007 Polaris Sportsman 700 800 - 800EFI Service Manual
      2008 Polaris Sportsman 500EFI & 500x2 Service Manual
      2008 Polaris Ranger 6x6 700EFI Parts Manual
      2008 Polaris 800 RZR Service Manual
      2008 Polaris Sportsman 700x2 - 800EFI - 800 Touring Service Manual
      2009 Polaris 850HD EPS Service Manual
      2009 Polaris Outlaw 450 & 525 Service Manual
      2009 Polaris Outlaw 90 Service Manual
      2009 Polaris Predator 50 Service Manual
      2009 Polaris Ranger 2x4 Service Manual
      2009 Polaris Ranger 4x4 Crew Service Manual
      2009 Polaris Ranger 500 2x4 Service Manual
      2009 Polaris Ranger 500EFI 4x4 Service Manual
      2009 Polaris Ranger 500EFI 4x4 Service Manual
      2009 Polaris Ranger 700 4x4 Crew Service Manual
      2009 Polaris Ranger 700 4x4 Service Manual
      2009 Polaris Ranger INTL Service Manual
      2009 Polaris Ranger RZR 170 Service Manual
      2009 Polaris Scramber 500 Service Manual
      2009 Polaris Sportsman 300 & 400HO Service Manual
      2009 Polaris Sportsman 450 & 500X2 Service Manual
      2009 Polaris Sportsman 500 Service Manual
      2009 Polaris Sportsman 6x6 800 Service Manual
      2009 Polaris Sportsman 800EFI & 800EFI Service Manual
      2009 Polaris Sportsman 550XP Service Manual
      2009 Polaris Sportsman 850XP Service Manual
      2009 Polaris Trail Boss - Trailblazer 330 Service Manual
      2010 Polaris Ranger RZR S Service Manual
      2011 Polaris Ranger RZR S Service Manual
      2011 Polaris Ranger RZR SW Service Manual
      2012 Polaris Sportsman 400 Service Manual
       
      Visit the Polaris Service Manual Section: https://www.quadcrazy.com/files/category/7-polaris-atv/ 
  • Similar Tagged Content

    • By gregj49
      Blows out black smoke when you rev it up how do you adjust the carb?
    • By chevyboy
      AL righty I did some trading around this weekend and ended up picking up a few 4 wheelers for cheap. I ended up with this one for $500 in it total and well the guy told me it dropped a valve. I haven't really messed with it at all. But this weekend I am going to try and start working on it some to get it running before winter time frame. So what I am asking is a couple of questions.
      1. First off where do I start I tried pulling the pull cord and could not get it to move at all.
      2. I need to get a service manual for this 4 wheeler where can I get it downloaded for free?
      3. what do I need to look for and how do I go about this really. I do have experience with 4 wheelers but this one is a little different to me than others because its a V2 and I have no clue where to start internal on the engines. Most of my experience is on the outside portion of troubleshooting on theses wheelers.
      Please no smart butt answers as i am new to here but just wanted opinions on where to start. Please and thanks wink:
    • By RoxanneRoseReid
      Need a polaris manual for a 1994 2 stroke 2/4x4 quad free. can you please post a link I can click on Thank you. Roxanne
    • By buzzar56
      I am looking for a free repair manual for a 2003 Polaris sportsman 500 ho atv. all the posts on here lead me noplace
      thanks fred.
    • By Mike8623
      Im looking for a atv fertilizer spreader that will spread bagged manure like Walmart sales. Does anyone have any recommendations or what have some of you used that will work with the bagged manure/fertilizer.
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...