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

Use the publication and specifications that match the vehicle configuration. Within the repair reference, the 2001–2003 supplement supplies revised procedures and directs readers to the preceding chapters for unchanged work.

The early volume covers multiple Gen II, III and IV chassis, 2x4, 4x4 and 6x6 layouts, and chain- and shaft-drive systems. Its 1996 general-specification sheets, printed pp. 1.5–1.8, are absent from this file.

Printable PDFs, Search and Diagram Detail

Text search and navigation: All four files have embedded bookmarks and searchable text sections. The early volume and repair reference have OCR text with recognition errors and some pages without searchable text. The 2001 and 2005 wiring sheets have searchable headings, but their internal labels are not searchable. Small wiring labels require zooming; the repair reference’s color diagrams are softer than the factory diagrams. In the 2005 file, the wiring-diagram bookmark opens the preceding starter-test chart.

The ZIP contains four printable PDFs totaling 1,830 pages, including covers, introductory material, indexes and wiring diagrams. Already included are the repair reference’s 33-page service supplement and one notes page, 20 blank pages in the early volume, two notes pages and the rear cover in the 2005 manual, and one notes page in the 2001 manual.

Engine Overhaul, PVT Service and Electrical Fault Tracing

These are selected content highlights, rather than a complete table of contents. Additional topics include replacement-key identification and storage preparation.

• Engine repair: Step-by-step removal, disassembly, inspection and assembly procedures for the covered two-stroke and four-stroke engines, with timing and lubrication-system service.

• Carburetion and fuel delivery: Mikuni VM and BST/CV carburetor overhaul, altitude-and-temperature jetting charts, needle-and-seat pressure testing and fuel-pump diagnosis.

• PVT and transmissions: Drive and driven clutch repair, belt alignment, bushing replacement, EBS service, shift-linkage adjustment and internal transmission repair for the identified configurations.

• Final drive and suspension: Demand 4 and Hilliard hub service, axle and U-joint repair, front gearcase work, 6x6 sprocket and eccentric service, and Fox shock repair.

• Hydraulic brakes: Bleeding, pad replacement, master-cylinder and caliper procedures, with separate rear-brake arrangements and model-specific service limits.

• Electrical diagnosis: Ignition, charging, starting, speed-limiter, ETC and AWD tests, model-specific wiring diagrams, and later instrument-cluster and ECM troubleshooting.

The Polaris factory manuals are written primarily for qualified ATV service technicians with mechanical knowledge, appropriate tools and a properly equipped shop.

Engine Inspection and Maintenance

The early volume covers EC25PF, EC28PF and EC38PL two-stroke repair, including crankshaft alignment, oil-pump end-play adjustment and oil check-valve testing. EH42PL and EH50PL four-stroke coverage extends to valve and cam timing, crankshaft installation, water-pump seals and internal wear inspection.

Maintenance sections provide periodic service schedules, lubricant and capacity tables, oil-pump adjustment and bleeding, valve-clearance work, coolant pressure testing, compression and cylinder-leakage checks, chain adjustment and toe alignment.

The four-stroke assembly section warns that incorrect cam-to-crank timing can cause serious internal engine damage. Its timing methods differ according to whether the stator and flywheel are installed.

Carburetor and Clutch Variants

The 2001 factory manual separates the Sportsman 500 DUSE’s BST 34 carburetor from the H.O. model’s BST 40. Their jetting, needle and float specifications are identified separately.

PVT coverage includes drive and driven clutch inspection, belt and offset checks, bushing replacement and Engine Braking System service. The early EBS section identifies the one-way clutch seals as vulnerable to damage if the driven clutch is opened from the wrong side.

The repair reference adds a revised driven-pulley assembly for 2003 models built after July 8, 2002. Its supplement also addresses later steering, rear-hub and brake changes.

Transmission, Chassis and Brake Service

The early volume provides internal repair procedures for Type III EZ Shift and Type IV shaft-drive transmissions. Its Type V section for the 1998 Scrambler 400/500 covers transmission removal.

Year-specific material distinguishes the dual-hydraulic rear brake used on the 1998 Scrambler 400/500 and Sportsman 500. The 2005 brake chapter identifies its front master cylinder as a nonserviceable assembly replaced as a unit.

Exploded views support component identification, but the factory manuals direct service-parts ordering to the applicable model-specific parts book.

Electrical Tests and Workshop References

Named references include the EH42PL/EH50PL oil-flow chart, Mikuni VM and BST carburetor exploded views, the Demand 4 front-hub view, the Type IV transmission exploded view and model-specific wiring diagrams for 1996, 1997 and 1998. Routing plates show Magnum wiring and fluid lines, 300 fan-motor wiring, Sportsman 500 oil-tank vent routing and engine-wire placement.

The 2001 manual separates early and late Sportsman 500 wiring. The 2005 manual adds Sure Power ECM operation, instrument-cluster diagnostic charts, coolant thermistor and fan tests, and a starter-system testing flowchart. These circuit-specific tests help distinguish wiring and supply faults from component faults before replacement parts are selected.

Special-tool references include the Mity Vac pump kit (P/N 2870975), drive clutch puller (P/N 2870506), clutch bushing kit (P/N 2871226), shaft-drive transmission tool kit (P/N 2871702) and Tektronix DMM 155 (P/N 2870659).

Examples of Carburetor Settings and Engine Inspection Limits

For the 2001 Sportsman 500 DUSE, the BST 34 float-height specification is 13.0 ± 1 mm. The Sportsman 500 H.O.’s BST 40 uses 14.7 ± 1 mm, so the carburetor variant matters when selecting adjustment data.

The 2005 EH50PL cylinder-head inspection section gives a warpage limit of 0.002 in. (0.05 mm), alongside the related inspection and replacement criteria.

Always observe standard shop safety protocols and verify the exact vehicle configuration, approved fluid type and component-specific torque requirements before beginning diagnostic or repair work.