1996-2003 Polaris Sportsman 500 ATV repair manual

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

• The price of this manual, handbooks, and repair guides are not set by our marketplace, but by the seller of the manuals themselves, so it is possible that the same manual is offered at a different price on another page here. Please compare prices before deciding to purchase.
• For many of our manuals, there are comments and ratings from other users at the end of the detail page to make your purchase decision easier. Please leave a review after your purchase to help other users make their purchasing decision.
• Don't hesitate and download the repair manual you need now. You get a lifetime guarantee for the download, as described in our FAQs FAQ.
• To contact the seller of the manual, please use our contact form, and we will forward your request or take care of it directly.