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Discussion Starter #1 (Edited)
Hey everyone, first post here! I've been looking around these forums for the past month or so, but I finally found something I think I need to start my own thread about.

I found a running 2001 500 for sale nearby. It seems in good shape, but I'm pretty sure that year is full time 4x4. I would want to make it selectable 4wd because I like to slide around when I don't need the 4wd. I have a 2003 parts bike. Will the front diff from the 2003 bolt into the 2001 chassis and work as long as they are the same drive ratio? I thought I found a thread that said an 03 or 04 500 front diff will work in an 02 500 chassis, but I can't find it again, and I haven't found anything for the 01. As far as I've read, the 01 and 03 have essentially the same Vinson 500 based engine with one being slightly detuned, so the prop shaft and all should be the same if they are both manual shift, correct?
 

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Discussion Starter #2
So update, the 2001 is an automatic, and it has selectable 4wd. The guy says it makes a grinding sound trying to go into 4wd, which sounds like the front diff is either low on fluid or going out. So I guess the question changes to if the diff is bad, will the diff from the 03 manual shift work with the 01 automatic?
 

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is the 4wd electric or manual lever on the 2003? the shifting happens in the nose cone. I would first check CV axle part numbers because that will tell you if the ring gear is compatible. then I would look at yoke/driveshaft design because the new diffs all have a removable nose cone where the 4wd shift takes place and that is also where your adaptation to the drive shaft/yoke happens. with a bit of research and measurement you may be able to make something work. I've put an 04 400 diff in an 02 500 before converted the diff from electric shift to manual by changing nose cone, and reinstalling linkages.
 

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Looking at parts diagrams it looks like your axle style is completely different and you will be doing ALOT of rigging and messing around to make that changeover work. I wouldn't be attempting this, your better bet would almost be to motor swap your 01 500 into the 03 500 chassis if that is the angle you are after. But again, could be a can of worms you are opening up. Good Luck on your adventure
 
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