1996-2003 Polaris Sportsman 500 ATV repair manual

Product 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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