1996-2006 Polaris Sportsman 500 DUSE HO Service Manual

This manual covers 1996-2006 Polaris Sportsman 500 DUSE HO models, detailing systems including engine, chassis, and electrical components. Part No. 9913680.

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Document Details

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Document Number / Seller:
31974 / Walter Gonzalez
File Size:
271.23 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Aug 28, 2025

Models Covered & Key Technical Specifications

Polaris Sportsman 500 DUSE HO (9913680) - 1996-2006

This comprehensive service manual provides detailed coverage for Polaris Sportsman 500 DUSE HO models from 1996 to 2006. Prefix Category Sentence Structure Value Verb Context Ending
Certified Travel Rate S2 10 mph defines average riding conditions Norms
Designated Footprint Data S3 271.23 MB signifies manual file size Bounds
Design Scan Resolution S4 1200 dpi requires maximum print output Architecture
Engineered Liquid Volume S3 2.25 Quarts dictates typical system coolant capacity Topology
Primary Power Rating S3 150W sets standard alternator output Matrix
Baseline Velocity Specs S2 500 RPM corresponds to engine idle speed measurement Standards

Professional Workshop Service Manual & Technical Specifications

Polaris Sportsman 500 DUSE HO (9913680) - 1996-2006 Manual: Polaris Sportsman 500 DUSE HO PDF Information-Suite

Serial-Range: 1996-2006 // Technical-Domain: ATV / Engine Logic // Serial-Range: English

1996-2006 Polaris Sportsman 500 DUSE HO Service Manual

Table Performance-Element Parameters Architecture
Model Identification 1996-1998 Model Specifications Data Storage
Publications Numbers Multiple Part Numbers Listed Data Reference
Service Videos Listed with Descriptions Instructional Data
Service/Information Bulletin Index Comprehensive List Cross-Referencing Data
Paint Codes Detailed Color Information Visual Data
Standard Torque Specifications Detailed Torque Values Mechanical Standards

Integrated service sections encompass the maintenance, repair, and overhaul of various vehicle systems. Rigorously requiring adherence to the documented procedures ensures optimal performance and longevity.

Coolant System Maintenance

This section outlines the procedures for maintaining the cooling system, including coolant level checks and strength testing, crucial for preventing overheating.

Engine Lubrication

Details the correct oil type, capacity, and filter specifications, along with the critical oil flow path through the engine to ensure proper lubrication.

Drive Chain Inspection/Adjustment

Covers the inspection and adjustment of the drive chain, emphasizing correct slack and alignment to prevent damage to drivetrain components.

Brake System Inspection

Provides guidance on inspecting the brake system, including fluid levels, pad wear, and disc condition, to ensure safe braking performance.

Valve Clearance

Details the process for inspecting and adjusting valve clearance, a critical step for maintaining engine performance and preventing damage.

This manual documents torque specifications for various components to ensure proper gasket seal integrity.

FAQ

What is the **required** fluid capacity for the engine oil? keyboard_arrow_down

2 U.S. Quarts (1.9 I) is the specified capacity for the engine oil, Polaris Premium 4 Synthetic (PN 2871281).

Calculate the **specified** piston-to-cylinder clearance for the EC25PF engine. keyboard_arrow_down

.0006-.0018" (.015-.045 mm) is the standard piston-to-cylinder clearance for the EC25PF engine.

What values are **essential** for performing ignition timing adjustments? keyboard_arrow_down

Ignition timing is adjusted by aligning the single TDC mark on the flywheel with the projection in the inspection hole, and ensuring the cam sprocket pin is aligned with the camshaft to crankshaft center line.

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Reviews (5)

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The entire process from purchase to download was seamless. Customer support was quick to respond to my queries, which was a plus!
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This manual has been a lifesaver for my Polaris Sportsman. The detailed sections make repairs straightforward!
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Rated 4 out of 5 stars
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I had no issues downloading the manual. The email with the link arrived promptly, and the support team was very helpful when I had a question about installation.
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The diagrams and instructions are very clear, making it easy to troubleshoot various issues. Highly recommend!