1999 Sportsman 500. Removing all the plastics in about 10 minutes.

This video will demonstrate how to, and how relatively quick it can be to remove the plastics from a 1999 Polaris Sportsman 500 and similar models. While I know its not practical to pull your plastics off for most basic repairs and maintenance. I have a few things to do on this machine and it'll give me the opportunity to really go through it. And an opportunity to show viewers some things with an unobstructed perspective. Hopefully helping some things make more sense. And make it easier to visualize what you're digging for, when you're doing stuff with the plastics on. Or maybe you're just here to see how to take yours off. Either way. I hope it's helpful. And check for the other videos I've made while I have it apart. I cover fixing the AWD, Speedometer, The rear brake, Recoil or pull start handle and/or rope, as well as some other things while it's all apart. If you find them helpful. Feel free to subscribe. Many more to come.
Link for a decent shop manual. amzn.to/3rFQW6p
It does not affect the price you would pay. Links are provided for convenience. But I may make a small commission (Usually pennies.) on any products purchased through the Amazon Assoc. Program. Via links provided. Thank you for your support.
Always be sure to follow your manufacturers specifications and requirements. This video is for demonstration purposes only.

[@gregbalvanz3124]

Greg here from Fairbanks, I’m about to start a deep dive into my 2001 Sportsman. We need a third ATV for visiting family and for my kids when they get older. I appreciate your videos a great deal. Thanks for making them. The White Mountains are calling!!!

[@ericinalaska7648]

Hey Greg. Thanks for the appreciation. Good luck with your diving. Heed the call.

[@micahjared8082]

thanks for sharing. its pretty trivial for the basic of simpleton mechanics, but its videos like this that show how truly easy it is to get into your machine and maintain her. cheers.

[@ericinalaska7648]

You're welcome! Appreciate the generous feedback.

[@supplykayo3049]

For the front bumper, I didnt have to take the front arm bar off. It's a weird angle you have to pull it out from the handle bar but its scratch free as well and saves time. Great video!

[@ericinalaska7648]

Appreciate it. Thanks.

[@MikeL-vu7jo]

I bought this exact machine brand spankin new back in 99 and I still have it and Have no complaints thanks

[@ericinalaska7648]

Yah it seems to have a good reputation.

[@markcraft2776]

Thank you for this. It helped tremendously.

[@ericinalaska7648]

Glad it helped. Im sure you've learned, or will learn a few things, maybe better or worse, along the way. Ive modified my approach since, no need to mess with the handlebars. Takes some finesse but doable. Just a bit of stretching and elongating and pulling.

[@tfd3576]

Thanks for the video ! I have to remove the gas tank and i was wondering how to remove the front plastics… that helps me a lot 👍

[@ericinalaska7648]

Glad It was of help. Thanks for the feedback.

[@mikejiskra7976]

Great Video, I will be doing the same shortly, Thanks Mike J from Nebraska.

[@ericinalaska7648]

Thanks and good luck. Theirs more than one way to come at it of course. I just wanted to show people who maybe really had no idea where to begin that it really is pretty simple. And the accessibility to things with the plastics off is a bonus. Thanks again.

[@JoshWeaverRC]

Sweet, just what I needed.

[@ericinalaska7648]

Well there you go.

[@denisbrazeau5031]

Thanks for the video, good stuff!!

[@ericinalaska7648]

Glad you enjoyed it. More to come.

[@jorgem2536]

Great video. you can take the front plastic off without taking light cover off or handle bars apart. just pull it off gas tank then turn it sideways and pull it over one handle bar at a time if angle right it will work tight but works nice looking wheeler you have there

[@ericinalaska7648]

Yes sir. Thanks for the mention. Sometimes I wish I could edit some of those details in after posting. But that's where the comments section comes in. I have actually had the front on and off a few times now as you described. Since making the video. Takes a bit more finesse or you could even say force. But definitely doable. Thanks again.

[@northernheat2585]

I just got all my plastic off without taking the handlebars off no problem. Just resurrected one of these thats been stored for over 10 years. These atv were beasts and still kick ass

[@ericinalaska7648]

Yah Im a fan. I really like it. It certainly can be done without messing with the handle bars. Just takes a little stretch. Ive actually been able to with no prob since the video.

[@karlbutz2158]

How did you do it without taking the speedometer pod apart?

[@jacobkea9091]

awesome video man, I just picked up a 98 sportsman 500 that has been sitting for a while and definitely needs some tlc, im about to attempt to replace the fuel pump, carb and choke so wish me luck, looking forward to more videos on this model since im not the most mechanically inclined person.

[@ericinalaska7648]

Glad it helped or inspired. You may have discovered already, but I have done a handful of other videos on this project. As well as unrelated stuff. Check out the playlists. Thanks for the support. And of course good luck!

[@grzlbr]

Nice !

[@ericinalaska7648]

Thanks!

[@mandmperformance665]

Thanks

[@ericinalaska7648]

Welcome

[@paulsmith869]

U make very videos eric .smitty from Newfoundland

[@ericinalaska7648]

I'll take it as a compliment. Perhaps lost in translation. You didnt say if the videos were very _______ or very _______ videos. I'll assume you were saying flattering things. Thank you. Eric from Alaska.

[@JeffyMor]

Hi Eric, I’ve appreciated all your Sportsman videos and they’ve helped me tremendously with my own projects. Thank you! Wondering if you could show in a little more detail how your winch is mounted? Not sure how to go about mounting one on mine with the way the rad is located. Looks like you have a mount that bolts into the rad screen mount?

[@ericinalaska7648]

Glad your finding the videos helpful. As far as the winch mounting goes. And my limited experience with mounting one on a machine that has never had one. It depends on the machine year make and model and the winch. There not all a one size fits all plug and play scenario. For example. I mounted a Harbor Freight winch on a 2000 Sportsman 500 and I had to, or chose to, take a router to the underside of the bumper to create a little clearance for it. I also learned that there are different after market mounting plates/adapters available for certain configurations. Some machines are all set up for certain winches and you can just mount it and it can be real simple. The wheeler in this video is currently a good distance away at the moment so I can't inspect it directly. But I did try to see if its demoed in another video a little better for you. Maybe the Coolant change video can offer some views or angles that would be of help. Best thing to do would be to try to search online or inquire maybe at a shop what the mounting options are for your specific year make and model. Theirs always a way to make something work or fit. Just depends on your ambition. The winch on this machine was already on it when I got it. And I hadn't really given it much attention other than to confirm it's functioning. But I do know it is a WARN brand that I believe was designed for Polaris and has a Polaris sticker on it. But I don't know if it came with or was an after thought and installed by a previous owner later. Hopefully that helps a bit.

[@JeffyMor]

@@ericinalaska7648 thank you for your reply. That was helpful. I checked online and found a KFI mounting plate that seems to mount how yours does to the radiator bracket and then the winch mounts to that. Reviews suggest it is compatible with the winch I have also so I will order that and give it a try. Thanks again!

[@jaywinters2483]

Good video. Question: How do you remove the socks from the feet after you've worn sandals?

[@ericinalaska7648]

Hahaha! I, am not an experienced sandal/flip flop wearer by any stretch of the imagination. That was a choice of convenience and an extremely rare if almost nonexistent one. In fact I noted it myself when editing and laughed a bit. But I certainly wasn't gonna start over again. All we can do hopefully is learn and grow from our choices and potential mistakes. But to answer your question. Seal puller. And a spotter. Seemed to get it done.

[@waltereldridge9447]

I just bought our first four wheeler, 1999 Polaris Sportsman 500 and I had to replace the brake master so far. I was in the process of freeing up the bleeders and I ended up breaking the front right one( if you're sitting on the bike) so now I have to tap it out. Question I have is how to bleed the brakes? A friend said just to "Crack" the front bleeders and let gravity do the work. Can this be done that way?

[@ericinalaska7648]

Hey there Walter. I actually have a video demonstrating exactly that. Im focusing on the rear brake but the process would be the same for the front. Of course using the appropriate hand brake and bleeder screw. kzbin.info/www/bejne/iJ24hIx5gdKVmKc

[@JanFugal]

Hey Eric, Jan Back here in NY again. 1996 sportsman 500, Was getting into the inner and outer tie rods replacement. Found the inner left Mounted under the two brackets on the steering column while on the right side the inner was mounted between the two brackets on the steering column. Two different bolts, left side had a sleeve between the two brackets. Somebody has messed with this! Also changing the outer TRods. How / where are the inners supposed to be located ? Video or diagram? Thanks as always.

[@ericinalaska7648]

Here is a link that should get you started and help a bit Id think. It has lots of great schematics. For your year. Likely what your talking about and more. Without laying eyes on exactly what your talking about its kind of hard to guess. But I think the schematics will help. www.manualslib.com/p/polaris+1996+sportsman+500.html And if your interested in a decent manual check out the link in the video description. Im always happy to help if I can but if some one got creative with the original assembly and I can't see it. Id only be guessing. Check out that link. Hope that helps. Let me know.

[@davebean2886]

Thank you for the videos. I recently purchased a 1999 Polaris Sportsman 500. I plan on studying all of your related videos. Do you do any consulting?

[@ericinalaska7648]

Happy to attempt to answer any questions if I can.

[@timkarsten3842]

I was wondering what the issue was with the 4x4?... i have a 2002 and it ended up being bad grounds to the switch

[@ericinalaska7648]

It was a transistor inside the speedo that had the soldiering fail. One of 3 transistors that are commonly problematic. I also made a video showing that repair. I had no lights, (On the speedo) no anything really regarding the speedometer. The switch wiring routes through the speedometer and triggers or engages the 4wd when you switch it on. On this year/model.1999 and similar. Since the speedometer was pretty much dead, no 4WD. Tested and reattached the transistor. And it all came back to life. I also had a 2002 that had wiring to the right front wheel severed and I had repaired that as well and made a video a few years back showing that repair. Thank you for adding another thing for people to check to the list. Comments like this are helpful to those who are troubleshooting and read them.

[@lebisamorales4819]

Hey, does anybody know how I can get a substitute for the left side panel? Mine is missing.

[@ericinalaska7648]

Not sure what year or model you have but I found this. www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwi3t8HV3ef5AhUpL0QIHRp8DzMQFnoECCQQAQ&url=https%3A%2F%2Fpicclick.com%2FPopular%2Fpolaris-sportsman-side-panel&usg=AOvVaw3hQHRVTWMaBxrI_XonlaPA

[@roninthenek4530]

When reintalling gas tank, do the front tabs go under the front frame rail? I have a 2001 sportsman and I cannot get the left front tab (shorter and wider than the right tab) in the slots on the frame.

[@ericinalaska7648]

Without the ability at the moment to see exactly what you're talking about, yours or mine, that's a tough one. Are you talking about the actual tank or the plastics that covers the tank? If you haven't already figured it out by the time Ive replied. Just take a moment to look things over and Im confident it'll make sense.

[@roninthenek4530]

@@ericinalaska7648 thank you for your response! I'm referring to the actual tank. There are 4 tabs: 2 in the rear that bolt onto the frame, and 2 in the front. Looking how the tank mounts from the front of the bike, the tab on the right iis longer and thinner than the one on the left. I've been at this for a couple of hours and just don't see how the left tab slides into the mounting hole. Can I send a picture?

[@ericinalaska7648]

@@roninthenek4530 Im digging out a manual. here real quick. Let me see if I can find something regarding that. My wheeler is not accessible at the moment to look at.

[@roninthenek4530]

@@ericinalaska7648 please don't inconvenience yourself. I have the Polaris shop manual and there is no reference to reinstalling the tank. I did find several other posts with guys having the same issue. It appears the tank's front tabs do seat under the frame rail. I just want to be sure before I button it all back up. BTW, superb video on the oil change. I've done many on vehicles but only one on a wheeler. The drawing of the crankcase was good advice, as I was going to skip right over it. Like you, I got about 16 ounces of oil.

[@ericinalaska7648]

I found this Polaris forum that seems to be addressing your issue. If you scroll down to the response. Someone copy and pasted the removal and reinstall instructions.2001-sportsman-500-gas-tank-installation.187789 Let me know how that works.

[@richbadour6002]

At 3:52 I just realized that in your title you were describing how long your video was and not how long it actually took for you to remove the plastic…… so could you give us a guess on how long it actual took with removing the screws and the bolts???

[@ericinalaska7648]

Id say 30 to 45 minutes perhaps? Assuming you have all your tools handy and a plan before you start. And surely after the first time you should get more efficient at it. All I really did when making the video that wasn't real time was remove some of the bolts in advance and pull off a few of the more stubborn pieces. But it didnt really add that much time. But I had done it before.

[@richbadour6002]

At about 1:30 Where were the screws on the side panels and how many?

[@ericinalaska7648]

The side panels snap in. No screws. Takes some effort and probably a few attempts you'll find what works best for you and how to come at them.

[@Jebs-xp3py]

I just need the front hood off I'm fixing my 2000 sportsman I'm trying to fix the four-wheel driver thank you

[@ericinalaska7648]

Good luck! Don't know if you saw but If you check the playlist. "Polaris Sportsman Repairs and Maintenance" I have a couple videos talking about some pos 4WD/AWD issues. kzbin.info/www/bejne/d3Wxqn1rqN1radE. and kzbin.info/www/bejne/o3zbYnpqj9SHiMk. Don't know if either applies to your scenario but maybe some of the stuff I ramble about will help.

[@Jebs-xp3py]

@@ericinalaska7648 me and my dad got it we just got to put it together now thanks tho and just realized my spelling sucked lol

[@ericinalaska7648]

@@Jebs-xp3py Anytime.

[@minifish7333]

First thing I see is socks with flip flops I’m done😂

[@ericinalaska7648]

Hahahahah!!!!!! Tactical flip flops Ive been told. It was a once in a lifetime event. And I also am offended. I offended myself. It was an in and out of the house repeatedly situation and they were by the door. Definitely not a fashion statement. They may not even be on properly. Hopefully you were able to get past the distraction and find some value in the rest of the video. I seriously actually cringed when editing it and considered editing that out. But got over it. Hopefully you can as well.

[@davebean2886]

Access to spark plug?

[@ericinalaska7648]

Look at the top of the motor under the gas tank. You'll need to pull the wire off which can be a knuckle buster. Not always but has the potential. Just come in from the side. If sitting on it the right.

[@asme1652]

this is helpful honestly but i don’t know which bolts go where😭

[@asme1652]

i just put them in a bucket like a month ago

[@ericinalaska7648]

Yah that'll take some patience and trial and error and process of elimination. Id sort them out and try to make sense of it that way first.

[@rawwetzel]

Yeppers it can be done. In editing the video

[@ericinalaska7648]

Hahahaha. Well yah. I guess I meant in a ten minute video. I see your point though. Not my intention. Didn't want to put anyone through watching me remove every screw. Just wanted to point them out and explain mainly for those that have zero experience or confidence never having done it. I do think that after you do it a time or two and if you have your tools ready. You could probably do it pretty close to that. Especially if you find something that works for you better a long the way. Anyway. Hope you didn't feel mislead. That really wasn't my intention. But I do now see that could be interpreted that way. No ones ever pointed that out all this time. Hope you at least got some helpful info out of it anyway. Thanks for watching.

[@kencor62655]

What a pain to even get the fuel tank cover off. Polaris loves to make everything more difficult than it should be. 2 minutes to do the same job on my Suzuki. Lol.

[@ericinalaska7648]

Yah Initially I thought it was a bit harder then it should be. But after a few times, no big deal. Like anything. Ive learned I really don't need to mess with the handlebars. Just kid of pull and elongate the opening and finesse it over. Other than that overall how do you like the Suzuki?

[@kencor62655]

@@ericinalaska7648 the Suzuki is so simple to work on. I like the suspension and brake setup. Of course I dont own anything to new, so everything requires work occassionally.

[@ericinalaska7648]

@@kencor62655 Yep. Thats the nature of recreational vehicles.

[@richbadour6002]

At 2:17 what was “”” this””” called?

[@ericinalaska7648]

Hahaha! I'll have to watch and see. But I'd think I was pointing at something of course. Its been a couple/few years since making that one.

[@ericinalaska7648]

Took a quick look. Panel? Hood? Cover? I have seen it referred to as a hood or nose hood. And it snaps in. No bolts.

[@MrFixit1]

The most difficult part of this job is, removing the 23 year old screws and bolts.

[@ericinalaska7648]

Can be a challenge. I pressure wash usually before going that deep. Certainly not nec. but helps.

[@66mitchb]

Tactical flip flops

[@ericinalaska7648]

Exactly. Hahaha! Wear those about twice a year. They were by the door and before I knew it I was turning on the camera and off and running. Well not running. Flippin and floppin. Tactically.

[@michaelpresey2273]

I just bought a Utility quad coming from sport quads and dirtbikes man when you tske all the plastics off you better be fixing the whole thing not like a dirtbike where you can take the whole thing apart in 2 hours of even like a sport quad everytying ks much more open and accessible. These things suck to take apart

[@ericinalaska7648]

Yah it's a whole different animal. Certainly no need to do it for most basic stuff or maintenance.

[@BackcountryHonda]

Sooooo, not 10 minutes....

[@ericinalaska7648]

Meaning I can show you in about ten minute how to. I see where you may have interpreted that differently. Wasn't intentional. Hope it was helpful though.

[@neilbrown3359]

These things are horrible

[@ericinalaska7648]

Yah. Bit more work than it seems it should be.

[@neilbrown3359]

@@ericinalaska7648 if I had whislindiesel money I would buy these things just to destroy them online!!!!

[@ericinalaska7648]

@@neilbrown3359 Hahaha. I cant recall the title but, there is a guy who didn't want to spend 20k to fix his non warrantied issue with his Tesla and he does so using dynamite.

[@dallasacuff9335]

Yea, the side panels never come off that easy. Pffffa

[@ericinalaska7648]

Yah they can be a bit of a wrestling match.