1996-2003 Polaris Sportsman 500 ATV repair manual

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Polaris 1996-2003 Polaris Sportsman 500 ATV repair manual - Technical Specifications

  • File Size: 52.00 MB
  • File Type: ZIP
  • Language: English
  • Printable: Yes
  • Estimated Download Time: 1.06 Minutes
  • Delivery Format: Digital (PDF) - Instant Access
  • Category: ATV
  • Brand: Polaris
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Polaris Models and Parts Covered in this ATV Manual

  • 1996 Polaris Sportsman 500
  • 1997 Polaris Sportsman 500
  • 1998 Polaris Sportsman 500
  • 1999 Polaris Sportsman 500
  • 2000 Polaris Sportsman 500
  • 2001 Polaris Sportsman 500
  • 2002 Polaris Sportsman 500
  • 2003 Polaris Sportsman 500
  • 2003 Polaris Sportsman 500 HO (High Output)
  • 2003 Polaris Sportsman 500 DUSE (Ducks Unlimited Special Edition)
  • 2003 Polaris Sportsman 500 RSE (Remington Special Edition)

Polaris 1996-2003 Polaris Sportsman 500 ATV repair manual - Complete Manual Information

Table of contents

Quick Reference Data

  • Quick Reference Data IX

Chapter One: General Information

  • Manual Organization
  • Notes, Cautions, and Warnings
  • Safety First
  • Cleaning Parts
  • Handling Gasoline Safely
  • Service Hints
  • Torque Specifications
  • Fasteners
  • Lubricants
  • Threadlocking Compound
  • RTV Gasket Sealant
  • Expendable Supplies
  • Serial Numbers
  • Warning and Information Labels
  • Basic Hand Tools
  • Precision Measuring Tools
  • Special Tools
  • Fabricating Tools
  • Mechanic’s Tips
  • Bearing Replacement
  • Seals
  • Storage

Chapter Two: Troubleshooting

  • Operating Requirements
  • Troubleshooting Instruments
  • Starting the Engine
  • Starting Difficulties
  • Engine is Difficult to Start
  • Engine Starting System
  • Charging System
  • Ignition System
  • Electronic Throttle Control
  • Fuel System
  • Engine Overheating
  • Engine
  • Engine Noises
  • Cylinder Leak Down Test
  • Power Train
  • Steering
  • Frame Noise
  • Brakes

Chapter Three: Lubrication, Maintenance and Tune-Up

  • Pre-Ride Check List
  • Tires and Wheels
  • Battery
  • Battery Electrical Cable Connectors
  • Periodic Lubrication
  • Periodic Maintenance
  • Unscheduled Inspection and Maintenance
  • Engine Tune-Up

Chapter Four: Engine Top End

  • Engine Principles
  • Engine Cooling
  • Engine Lubrication
  • Servicing the Engine in the Frame
  • Exhaust System
  • Cylinder Head Cover
  • Rocker Arm Assembly
  • Camshaft
  • Cylinder Head
  • Valves and Valve Components
  • Cylinder Block
  • Piston and Piston Rings
  • Camshaft Chain and Sprockets
  • Break-In Procedure

Chapter Five: Engine Lower End

  • Engine
  • Flywheel and Stator Plate
  • Recoil Starter
  • Crankcase
  • Crankshaft Inspection
  • Balancer Shaft Inspection
  • Shaft End Float Measurement and Shim Selection
  • Oil Pump
  • Oil System One-Way Check Valve
  • Break-In Procedure

Chapter Six: Fuel System

  • Carburetor Operation
  • Carburetor
  • Carburetor Cleaning and Inspection
  • Carburetor Tests and Adjustments
  • Throttle Cable Replacement
  • Starting Enrichment (Choke) Cable
  • Fuel Tank
  • Fuel Shutoff Valve
  • Air Filter Air Box
  • Fuel Pump

Chapter Seven: Cooling Systems

  • Polaris Variable Transmission (PVT) Air Cooling System
  • Engine Cooling System
  • Safety Precautions
  • Hoses and Hose Clamps
  • Engine Gaskets/Seals
  • Cooling System Inspection
  • Radiator
  • Cooling Fan
  • Coolant Pump
  • Thermostat
  • Temperature Sensors

Chapter Eight: Clutch/Drive Belt System

  • Drive Unit
  • Drive Pulley
  • Special Tools
  • Driven Pulley
  • Drive Belt
  • Drive Pulley
  • Driven Pulley
  • Clutch Outer and Inner Cover (All Models)

Chapter Nine: Transmission

  • Transmission
  • Transmission Inspection
  • Shift Shafts
  • Front Output Shaft
  • Transmission Gearcase Oil Seal Inspection and Replacement
  • Shift Selector Linkage

Chapter Ten: Front Drive System

  • Front Hub and Hillard Clutch
  • Front Drive Axle, Boots, and CV (Constant Velocity) Joints
  • Front Drive Shaft
  • Front Drive Unit

Chapter Eleven: Electrical System

  • Basic Information
  • Negative Battery Terminal
  • Charging System
  • Alternator Stator
  • Voltage Regulator/Rectifier
  • Capacitor Discharge Ignition
  • Ignition Coil
  • Ignition Stator Coils
  • Electric Starting System
  • Starter Drive Gears
  • Starter Solenoid
  • Lighting System
  • Electrical Components
  • Switches
  • Wiring Diagrams

Chapter Twelve: Front Suspension and Steering

  • Front Wheel
  • Front Hub
  • Front Strut Cartridge and Spring
  • Front Strut/Spindle
  • Control Arm
  • Handlebar
  • Tie Rods
  • Steering Shaft
  • Tires and Wheels

Chapter Thirteen: Rear Suspension

  • Rear Wheels
  • Tire Changing and Tire Repairs
  • Shock Absorber
  • Rear Hub and Bearing Carrier
  • Rear Axles
  • Upper Control Arm
  • Lower Control Arm
  • Upper and Lower Control Arm Inspection
  • Stabilizer Linkage
  • Stabilizer Support

Chapter Fourteen: Brakes

  • Disc Brakes
  • Front Brake Pad Replacement
  • Front Caliper
  • Output Shaft Brake Pad Replacement (1996-1997 Models)
  • Output Shaft Brake Caliper (1996-1997 Models)
  • Output Shaft Brake Pad Replacement (1998-On Models)
  • Output Shaft Brake Caliper (1998-On Models)
  • Front Master Cylinder
  • Rear Master Cylinder
  • Brake Hose Replacement
  • Rear Brake Pedal
  • Rear Brake Lever (1996-1997 Sweden Models)
  • Foot Brake (1998-On Sweden Models)
  • Brake Disc
  • Bleeding the System

Chapter Fifteen: Body

  • Seat
  • Front Rack and Grille
  • Side Panels
  • Front Fender
  • Front Bumper (Models So Equipped)
  • Radiator Guard
  • Rear Rack
  • Rear Fender
  • Footwells
  • Rear Bumper (Models So Equipped)

Supplement: 2001-2003 Service Information

  • Starting the Engine
  • Ignition System
  • Periodic Maintenance
  • Engine Tune-Up
  • Cylinder Block
  • Piston and Piston Rings
  • Engine
  • Flywheel and Stator Plate
  • Carburetor (Sportsman 500 H.O. Models)
  • Cleaning and Inspection
  • Carburetor Tests and Adjustments
  • Drive Belt
  • Driven Pulley (2003 Models Built After 07/08/02)
  • Transmission
  • Lighting System
  • Electrical Components
  • Steering Shaft (2002-On Models)
  • Rear Hub and Bearing Carrier (2003 Models)
  • Rear Brake Pad Replacement (2003 Models)
  • Rear Calipers (2003 Models)
  • Front Master Cylinder (2003 Models)
  • Rear Master Cylinder (2003 Models)
  • Brake Hose Replacement (2003 Models)

Index

  • Index 470

Wiring Diagrams

  • Wiring Diagrams 476

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Frequently Asked Questions - Polaris ATV Manual

What does this Polaris manual cover?

This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for 1996-2003 Polaris Sportsman 500 ATV repair manual. It includes information for the following models: - 1996 Polaris Sportsman 500 - 1997 Polaris Sportsman 500 - 1998 Polaris Sportsman 500 - 1999 Polaris Sportsman 500 - 2000 Polaris Sportsman 500 - 2001 Polaris Sportsman 500 - 2002 Polaris Sportsman 500 - 2003 Polaris Sportsman 500 - 2003 Polaris Sportsman 500 HO (High Output) - 2003 Polaris Sportsman 500 DUSE (Ducks Unlimited Special Edition) - 2003 Polaris Sportsman 500 RSE (Remington Special Edition) .

Is this manual suitable for beginners?

Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for ATV maintenance and repair.

What file format will I receive?

You will receive this manual as a ZIP file (52.00 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.

How quickly can I access the manual after purchase?

You'll receive instant access to your Polaris ATV manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.

Can I print specific sections of the manual?

Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.

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Comments

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James L.says...
If you own a Polaris Sportsman, you need this manual. The maintenance tips and detailed diagrams helped me do repairs I thought were impossible. Excellent service!
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Sarah P.says...
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Mark T.says...
This manual was exactly what I needed to get my Polaris Sportsman back on the trail. The troubleshooting section is detailed and easy to follow. Highly recommend!
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Emily R.says...
I was pleasantly surprised by the depth of information in this manual. Downloading was a breeze, and the support team was quick to respond to my questions. Worth every penny!