2000 Polaris Sportsman 500 Rear Suspension Parts: A Complete Guide

The rear suspension of a 2000 Polaris Sportsman 500 is a key system that affects ride comfort, handling, and towing stability. Over time, components wear out or break, especially if the machine is used for heavy work or trail riding. Whether you are replacing worn parts or upgrading for better performance, understanding the available options helps you make the right choice. This article covers the essential rear suspension parts, common problems, and practical advice for selection and installation.

Understanding the Rear Suspension

The 2000 Polaris Sportsman 500 uses an independent rear suspension (IRS) design. It consists of two trailing arms, a rear sway bar, coil-over shocks, and multiple bushings. The system allows each rear wheel to move independently, improving traction on uneven terrain. The stock setup is tuned for a balance of comfort and load capacity, but owners often want to replace parts with OEM equivalents or upgrade to aftermarket options for better damping or durability.

Common Issues with the 2000 Sportsman 500 Rear Suspension

• Leaking or worn shocks: The original shocks lose gas and oil over time, leading to bottoming out and a harsh ride.
• Broken springs: Springs can sag or break due to heavy loads or corrosion.
• Worn bushings: Control arm and sway bar bushings deteriorate, causing clunking noise and loose handling.
• Bent trailing arms: Striking rocks or stumps can bend the trailing arms, affecting alignment.
• Sway bar link failure: The small links that connect the sway bar can break, reducing roll resistance.

Regular inspection is important. If you notice excessive bouncing, uneven tire wear, or strange noises, it is time to look at suspension parts.

Rear Suspension Parts Overview

Shocks (Rear)

The rear shocks are the primary damping components. For the 2000 model, you have two options: OEM replacement or aftermarket upgrades.

• OEM shocks: Polaris part number 2203000-xxx (verify exact number based on VIN). They are affordable and restore original ride quality. However, they may not last as long as aftermarket options.
• Aftermarket shocks: Brands like Works Performance, Progressive Suspension, or Fox offer shocks with adjustable damping and heavier springs. For a Sportsman 500 used for plowing or hauling, a stiffer shock can improve stability.

When selecting shocks, ensure they are rated for the machine's weight (curb weight ~700 lbs) and intended use. Measure ride height before removal; a shock that is too long can cause binding.

Springs

Springs determine ride height and support. The 2000 Sportsman 500 uses coil-over springs that can be replaced separately. If the spring is sagging or broken, replace it. Aftermarket springs often come in different rates (soft, medium, heavy). For trail riding, a medium rate works well. For heavy towing, a heavy rate is better.

• Spring dimensions: Typical free length is around 14 inches, with an inside diameter of about 2.5 inches. Confirm with supplier.
• Material: Chrome silicon or 5160 steel are common. Avoid painted springs as they rust quickly.

Bushings and Bearings

The rear suspension has multiple pivot points: trailing arm pivots, sway bar links, and shock mounts. Worn bushings create slop and noise.

• Control arm bushings: Polyurethane bushings are a popular upgrade over rubber. They provide tighter handling and last longer. Available from energy suspension or aftermarket ATV brands.
• Sway bar bushings: Replace if cracked or hard. Use silicone grease during installation to prevent squeaking.
• Shock eyelet bushings: Often forgotten, these rubber isolators wear out. Replace them when installing new shocks.

Rear Sway Bar

If the sway bar is bent or the links are damaged, replace the entire bar or just the links. An aftermarket sway bar can have a thicker diameter for reduced body roll. However, for most users, OEM replacement is sufficient.

Trailing Arms (A-Arms)

The trailing arms on the 2000 model are steel but prone to bending. If damaged, you can bend them back (if slight) or replace. Aftermarket tubular arms are lighter and stronger but expensive. For budget repairs, find a used part from a salvage yard.

How to Choose Replacement Parts

Consider the following factors:

• Intended use: Trail riding, hunting, utility work, or sport riding. For general use, OEM quality shocks and poly bushings are a good balance. For extreme conditions, invest in shock upgrades.
• Budget: A pair of OEM shocks costs around $80-120 each, while aftermarket can be $150-300 each. Springs are $40-80 per pair. Bushings are cheap ($20-40 per set).
• Quality: Avoid no-name brands. Stick with known manufacturers like Polaris, Works, Progressive, or OEM suppliers (e.g., KYB).
• Compatibility: Always verify fitment for the 2000 Sportsman 500. Some aftermarket parts are shared with 2001-2002 models, but not always.

Installation Tips for Rear Suspension Parts

Working on the rear suspension is straightforward for a DIY mechanic. Basic tools: jack stands, socket set, wrenches, pry bar, torque wrench, and penetrating oil.

1. Safety first: Use jack stands under the frame, not the trailing arms.
2. Remove the rear wheels: Gives easier access.
3. Shock removal: Unbolt top and bottom. Compress the shock with a tool if needed (coil spring compressors are optional).
4. Spring replacement: If replacing just the spring, use a spring compressor to remove tension from the shock assembly.
5. Bushing press: Use a proper bushing press or a vice with sockets. Heat can help loosen seized bushings.
6. Torque specs: Tighten all bolts to factory specifications (e.g., trailing arm pivot nuts: 40 ft-lbs; shock bolts: 30 ft-lbs). Grease pivot points.

If you are not comfortable, a local ATV shop can handle installation, saving time and frustration.

Maintenance Tips for Long Life

• Clean and grease: After muddy rides, wash the suspension and apply grease to zerk fittings if present.
• Inspect boots: Shock dust boots prevent dirt from damaging seals. Replace if torn.
• Check bolt tightness: Vibrations can loosen bolts. Annually re-torque suspension fasteners.
• Replace bushings at first sign of play: Early replacement saves other components from wear.

Final Recommendation

For a 2000 Polaris Sportsman 500 used for normal trails and light work, start with a set of OEM shocks and polyurethane bushings. This combination restores ride quality and tightens handling at a reasonable cost. If you regularly carry heavy loads or tow, upgrade to aftermarket shocks with heavier springs. Avoid cheap generic parts; they often wear out quickly and can compromise safety. Always use proper tools and torque specs for installation. With the right parts and care, the rear suspension will give many more miles of reliable service.