- 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)
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
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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