There’s a reason the 2000 Polaris Sportsman 500 is a legend in the ATV world. It’s a tough, reliable workhorse that’s hauled more gear and explored more trails than most of us can count. But let’s be honest, even legends show their age, and after two decades, some quirks are bound to pop up.
You’re probably here because you’re wrestling with one of those quirks right now. Maybe the All-Wheel Drive isn’t kicking in when you’re axle-deep in mud, or it just refuses to start without a fight. You love your machine, but you need it to work when it counts.
We promise this guide will cut through the frustration. We’re going to walk you through the most common 2000 polaris sportsman 500 awd problems, from simple electrical checks to deep-diving into the drivetrain. You’ll learn how to diagnose the issue, what tools you’ll need, and how to perform the fixes yourself, getting you back on the trail with confidence.
The Heart of the Beast: Common Problems with 2000 Polaris Sportsman 500 AWD Problems
While this ATV is built like a tank, a few key areas are notorious for causing headaches. Understanding these common failure points is the first step in any successful diagnosis. Think of it as a roadmap to finding the root of your issue quickly.
Most issues you’ll encounter fall into four main categories: the signature Polaris On-Demand AWD system, fuel and carburetor troubles, electrical gremlins, and general mechanical wear and tear. This guide will provide actionable 2000 polaris sportsman 500 awd problems tips for each category.
Don’t just throw parts at the problem. A methodical approach will save you time, money, and a lot of skinned knuckles. Let’s get our hands dirty and figure out what your Sportsman is trying to tell you.
Diagnosing the #1 Culprit: The All-Wheel Drive (AWD) System
The On-Demand AWD is what makes a Sportsman a Sportsman, but when it acts up, it’s a major pain. The good news is that the system is relatively simple, and the fixes are often straightforward once you know what to look for.
Understanding Polaris ‘On-Demand’ AWD
Before you can fix it, you need to know how it works. Your front hubs contain a Hilliard clutch. When you flip the AWD switch, it sends power to an electromagnetic coil in each hub. This magnetism engages an armature plate, which locks the clutch and sends power to the front wheels—but only when the rear wheels slip.
It’s not a full-time 4×4 system. It’s designed to engage “on-demand.” Understanding this is key to proper diagnosis.
Symptom: AWD Not Engaging
This is the most common complaint. You’re stuck, the rear wheels are spinning, and the fronts are doing nothing. Here’s your step-by-step checklist:
- Check the Obvious: Is the AWD switch on the handlebar turned on? Is the ATV in gear (not Neutral)? It sounds simple, but it catches people all the time.
- Listen for the “Clunk”: With the key on and engine off, flip the AWD switch. You should hear a faint “clunk” from the front hubs as the magnetic coils engage. No clunk means no power is getting to the hubs.
- Check the Fuses: Locate your fuse box and check for any blown fuses related to the AWD system.
- Inspect the Wiring: Trace the wires from the handlebar switch down to each front hub. Look for any breaks, corrosion, or unplugged connectors. These wires live a hard life and are prone to damage.
- Test for Power: If the wiring looks good, use a multimeter to check for 12 volts at the connector going into the hub when the switch is on. If you have power here, the problem is inside the hub. If not, the issue is with your switch or wiring.
- Check Hub Fluid: The wrong fluid will cause major problems. These hubs require Polaris Demand Drive Fluid. If someone filled it with regular gear oil, it won’t work correctly. Drain the hubs and refill with the proper fluid.
Symptom: AWD Stays Engaged or Makes Noise
Sometimes the problem is the opposite—the AWD won’t turn off, or you hear grinding noises. This often points to a mechanical issue inside the hub.
The most likely cause is a broken or warped armature plate. These thin metal plates can crack over time, causing them to bind up and keep the AWD locked. You’ll need to disassemble the hub to inspect and replace the plate if necessary.
Fuel and Air Woes: Carburetor & Starting Issues
If your Sportsman is hard to start, won’t idle, or bogs down when you hit the throttle, your first suspect should be the Mikuni carburetor. Ethanol in modern fuel can wreak havoc on these older carbs.
The Classic Hard Start or No Start
You pull and pull, or crank and crank, but it just won’t fire up. Before you blame the engine, focus on the fuel system.
- Stale Fuel: Gas that’s more than a few months old can be your worst enemy. Drain the tank and the carburetor bowl and fill up with fresh, non-ethanol fuel if possible.
- Clogged Jets: The pilot jet, which controls fuel at idle, has a tiny opening that clogs easily. A thorough carb cleaning is often the best solution. You can get a carburetor rebuild kit for a reasonable price.
- Choke Adjustment: Make sure your choke cable is properly adjusted and the plunger is moving freely. A stuck choke can make starting impossible.
Poor Idle and Bogging Down
If the engine starts but runs rough or dies when you give it gas, you’re likely dealing with an air/fuel mixture problem. After a good cleaning, you can make small adjustments to the idle screw (for idle speed) and the air/fuel mixture screw (for fine-tuning). Turning the air/fuel screw out makes the mixture richer; in makes it leaner. Start at about 2.5 turns out from lightly seated.
Electrical Gremlins: Battery, CDI, and Stator Problems
Intermittent issues are often electrical. A solid understanding of the basics can help you track down these frustrating gremlins. This section serves as a helpful part of your 2000 polaris sportsman 500 awd problems guide.
Is Your Battery Really the Problem?
A weak battery can cause a host of strange symptoms, including a weak spark and issues with the AWD engagement. A fully charged ATV battery should read about 12.6-12.8 volts. More importantly, check the voltage while cranking the engine. If it drops below 9.5-10 volts, the battery is likely on its way out.
Also, check that your charging system is working. With the engine running at a high idle, you should see 13.5-14.5 volts at the battery terminals. If not, you may have a bad voltage regulator or stator.
When to Suspect the CDI Box or Stator
If you have no spark at all, and you’ve confirmed your battery and kill switch are good, the problem might be the CDI (Capacitor Discharge Ignition) box or the stator. You can test the resistance values of the stator using a multimeter and compare them to the specs in a service manual. This is a more advanced check, and if you’re not comfortable with electronics, this is a good time to consult a professional mechanic.
A Proactive Approach: Best Practices and a Care Guide
The best way to deal with problems is to prevent them. Following a few 2000 polaris sportsman 500 awd problems best practices will dramatically increase your machine’s reliability and lifespan. This is the core of any good 2000 polaris sportsman 500 awd problems care guide.
Your Regular Maintenance Checklist
- Engine Oil & Filter: Change it every 25-50 hours of use, depending on conditions.
- Air Filter: Clean and re-oil your air filter after every dusty ride. A clogged filter chokes your engine.
- Hub & Transmission Fluids: Check these levels regularly and change them at least once a year. Use the correct Polaris-spec fluids!
- Grease Zerks: Hit all the grease fittings on your suspension and driveshaft every 10-15 hours to keep things moving smoothly.
- Battery Terminals: Keep them clean and tight to ensure a solid electrical connection.
Sustainable Ownership: Making Your Sportsman Last
Keeping this classic ATV running is a great example of sustainable and eco-friendly practice. Instead of buying new, you’re repairing and maintaining. When you change fluids, always dispose of them properly at a local auto parts store or recycling center. Using high-quality parts and performing preventative maintenance means fewer breakdowns and less waste in the long run.
Frequently Asked Questions About 2000 Polaris Sportsman 500 AWD Problems
What type of fluid do I use in the front hubs?
This is critical. You MUST use Polaris Demand Drive Fluid. Using standard gear oil or ATF will cause the Hilliard clutch system to either not engage or lock up permanently. Don’t substitute this fluid.
Why does my battery keep dying?
If you’ve confirmed the battery itself is good, the two most likely culprits are a faulty voltage regulator that isn’t charging the battery while running, or a “parasitic draw” that is draining the battery while the key is off. A bad regulator is more common on these models.
How do I know if my carburetor needs to be rebuilt?
If a simple cleaning doesn’t solve your issues with bogging, poor idling, or fuel leaking from the overflow tubes, it’s time for a rebuild. A rebuild kit is inexpensive and replaces all the critical seals, O-rings, and jets that wear out over time.
Is the 2000 Polaris Sportsman 500 a reliable ATV?
Absolutely. For its age, it is an incredibly robust and capable machine. Like any vehicle over 20 years old, it has its known quirks. But with consistent maintenance and by addressing the common issues outlined in this guide, it can provide many more years of reliable service.
Tackling these issues yourself is not only rewarding but also deepens your connection with your machine. Take your time, be methodical, and don’t be afraid to consult a service manual. Now you have the knowledge to diagnose and fix the most common issues that plague this legendary quad.
Stay safe on the trails, and happy wrenching!
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