1996–2006 Polaris Sportsman 500 DUSE HO Service Manual (P/N 9913680)

271.23 MB • Printable PDFs (ZIP Download)

4.6starstarstarstarstar_half(5)
visibility Preview Available
$18.30 Original OEM Factory Manuals & Data Instant Download / No Shipping Fees
OR BUY NOW
verified_user
Lifetime Access
Re-download anytime
flash_on
Instant Download
Get it immediately
lock
Secure Payment
PayPal

Polaris Models Covered & Key Technical Specifications

Models: Polaris Sportsman 500, Trail Blazer, Trail Boss, Xplorer 300, Xpress 300, Xpress 400, Xplorer 400, Sportsman 4x4, 400 6x6, Magnum 2x4, Magnum 4x4, Magnum 6x6, Sport 400, Xplorer 500, Scrambler 500, Big Boss 500 6x6
Sub-models / Variants: 2x4, 4x4, 6x6, Gen II, Gen III, Gen IV, Shaft Drive, Chain Drive
Model Years: 1996–2006
Serial Numbers: 96-10273 (example), 9913680 (manual ref)
Technical Data:

  • Engine Displacement: 244cc, 283cc, 378.7cc, 425cc, 498cc
  • Engine Type: 2-stroke and 4-stroke configurations
  • Fuel Capacity: 3.5 to 5.25 US Gallons
  • Transmission Type: PVT (Polaris Variable Transmission), Shaft Drive, Chain Drive
  • Spark Plug: NGK BR8ES, BKR5ES, BKR5E
  • Spark Plug Gap: 0.024–0.028 in (0.6–0.7 mm)
  • Engine Oil Capacity: 2 to 3 Quarts
Technical Specifications
keyboard_arrow_down
Document Number / Seller:
31974 / Walter Gonzalez
File Size:
271.23 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Jun 6, 2026

Polaris Manual Features & Content Preview

This official OEM publication (P/N 9913680 and 9914752, 1998 revision) delivers exactly what you need for routine maintenance, engine tuning, and chassis service. Built for workshop professionals and DIY mechanics, this 56-page reference guide skips the fluff and provides direct access to vital component data for both 2-stroke and 4-stroke drivetrain configurations.

For fast diagnostics, the documentation highlights specific reference values, including 500 RPM idle speed settings for specific engines and 115 PSI compression limits for 2-stroke models. You also get exact component identification tables and complete lubrication charts to ensure equipment longevity.

Component Data and Shop Features:

  • Complete fluid capacity charts for engine oil, transmission lubricant, and cooling systems
  • Fuel system specifics including pilot screw settings, main jet sizes, and needle specifications
  • Clear system routing diagrams for wiring harnesses, fuel lines, and coolant hoses
  • Standard bolt torque guidelines to ensure accurate assembly

Note: Always observe standard shop safety protocols and verify your exact vehicle configuration, fluid types, and torque requirements before beginning any diagnostic or maintenance work.

Technical Safety Notice
keyboard_arrow_down

This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Customer Reviews

Read what our customers say about this Polaris ATV manual and share your own experience.