Product Information
Table of Contents
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 checklist
- 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
- Rear master cylinder (2003 models)
- Rear brake disc (2003 models)
- Brake hose replacement (2003 models)
Index
Wiring Diagrams
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