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Polaris Sportsman Xplorer 500 ATV Workshop Service Repair Manual 1996-2003 # 1 Download
With this in-depth & highly detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your investment, keeping your vehicle in pristine condition. With step by step instruction & highly detailed exploded pictures to show you how to complete the required job correctly & efficiently.
Covers the entire vehicle from start to finish, as used by professional mechanics to service or repair your vehicle. Below is a example of the topics this manual covers, an absolute wealth on information at your finger tips.
COVERS:
======
1996 Sportsman 500
1997 Sportsman 500
1997 Xplorer 500
1998 Sportsman 500
1998 Worker 500
1999 Sportsman 500
1999 Worker 500
1999 Sportsman 500 RSE
2000 Sportsman 500
2000 Worker 500
2000 Sportsman 500 RSE
Sportsman 500 Remington Special Edition (Cam ouflage color scheme).
2001 Sportsman 400
2001 Sportsman 500 DUSE
2001 Sportsman 500 H.O.
2001 Sportsman 500 HO
2002 Sportsman 400
2002 Worker 400 (International)
2002 Sportsman 400 ASEI
2002 Sportsman 400 DUSE
2002 Sportsman 500 H.O .
2002 Worker 500 (International)
02 Sportsman 500 RSEl
02 Sportsman 500 DUSE1
02 Sportsman 500 H.O. Desert
02 Sportsman 500 https://www.tradebit.comedom
2003 Sportsman 400
2003 Sportsman 500 H.O.
2003 Sportsman Ducks Unlimi ted Special Edition (DUSE)
03 Sportsman Remington Special Edi tion (RSE )
03 Sportsman 400
03 Sportsman 400 Desert
CONTENTS
QUICK REFERENCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
CHAPTER ONE .
GENERAL INFORMATION
Manual organization
Notes, cautions and warnings
Safety first
Cleaning parts
Handling gasoline safely
Service hints
Torque sped fication s
Fas teners
Lubrica nts
Threadlocking compound
RTV gasket sealant
CHAPTER TWO . . . . .
TROUBLESHOOTING
Operatin g requirement s
Troubleshooting instruments
Starting the engine
Start ing diffi culties
Engine is difficult to start
Engine starting system
Charging system
Ignition system
Electronic throttle control
.. .. .. . 1
Expendable supplies
Serial numbers
Warning and information labels
Basic hand tools
Precision measuring tools
Special tools
Fabricat ing tools
Mechanics tips
Bearing replacement
Seals
Storage
.. 36
Fue l sys tem
Engine overheating
Engine
Engine noises
Cy linder leak down test
Power tra in
Steering
Frame noise
Brakes
CHAPTER THREE . .. .... .. .. . .. .
LUBRICATION, MAINTENANCE AND TUNE-UP
Pre- ride check list
Tire s and whee ls
Battery
Batt ery elec tr ica l cabl e connectors
Perio dic lubrication
CHAPTER FOUR .
ENGINE TOP END
Eng ine prin cip les
Eng ine cooling
Eng ine lubrication
Servicing the engine in the frame
Exha ust syst em
Cy linder head co ver
Rocker ann assembl y
CHAPTER FIVE . . .
ENGINE LOWER END
Engine
Flywheel and stator plate
Recoi l starte r
Cra nkcase
Crankshaft inspec tion
Balancer shaft inspection
CHAPTER SIX . . . .
FUEL SYSTEM
Carburetor operation
Carburetor
Carburetor cleaning and inspection
Carburetor tests and adj ustments
Throttle cable replacemen t
CHAPTER SEVEN. . . . . . . . .
COOLING SYSTEMS
Polaris va riabl e transmission (PVT)
air cooling system
Engine cooling sys tem
Safety precauti ons
Hoses and hose clamps
Engin e ga skets/sea ls
.... .. 53
Perio dic main tenance
Unsc heduled inspection
and ma intenance
Engine tune-up
.. .. .. ...... 94
Camshaft
Cy linde r head
Valves and va lve components
Cylinder block
Piston and piston rings
Camshaft chain and sprockets
Break-in pro cedure
. . . 137
Shan end float measurement
and shim select ion
Oil pumr
Oil system one-way c heck valve
Break -in pro cedure
175
Stalling enr ichment (choke) cab le
Fuel tank
Fuel shutoff va lve
Air fi lter air box
Fu l pllm p
.... 198
Coo ling sys tem inspect ion
Radiator
Coo ling fan
Coo lant pump
Therm ostat
Temp erature se nsors
CHAPTER EIGHT .
CLUTCH/DRIVE BELT SYSTEM
Drive unit
Drive pulley
Specia l tools
Driven pulley
Drive belt
CHAPTER NINE .
TRANSMISSION
Transmission
Transmission inspection
Shift shafts
Front output shaft
CHAPTER TEN . . . . . . .
FRONT DRIVE SYSTEM
Front hub and Hillard clutch
Front drive axle, boots and CV
(constant velocity) joints
CHAPTER ELEVEN . .
ELECTRICAL SYSTEM
Basic informat ion
Negative battery terminal
Charging system
Alternator stator
Voltage regulator/rectificr
Capacitor discharge ignition
Ignition coil
Ignition stator coils
CHAPTER TWELVE .
FRONT SUSPENSION AND STEERING
Front wheel
Front hub
Front strut cartridge and spring
Front strut/spindle
Control arm
CHAPTER THIRTEEN .
REAR SUSPENSION
Rear wheels
Tire changing and tire repairs
Shock absorber
Rear hub and bearing carrier
Rearaxles
Upper control arm
. .. .. .. .... 213
Drive pulley
Driven pulley
Clutch outer and inner cover
(all models)
. . 249
Transmission gearcase oil seal
inspection and replacement
Shift selector linkage
..... .... 290
Front dr ive shaft
Front drive unit
.. .. . 303
Electric starting system
Starter drive gears
Starter solenoid
Lighting system
Electrical components
Switches
Wiring diagrams
. 337
Handlebar
Tie rods
Steerin g shaft
Tires and wheels
. 362
Lower control arm
Upper and lower control
arm inspection
Stabilizer linkage
Stabilizer support
CHAPTER FOURTEEN.
BRAKES
Disc brakes
Front brake padreplacement
Front cal iper
Ou tput shaft brake pad replacement
(1996-1997 mode ls)
Output sha ll brake cal iper
( ]996- 1997 mode ls)
Output sha ll brake pad repl acement
( I998- on models)
Output shaft brake caliper
(I 998-on models)
CHAPTER FIFTEEN
BODY
Seat
Front rack and grille
Side panels
Front fender
Fro nt bum per (models so eq uipped )
SUPPLEMENT .
2001-2003 SERVICE INFORMATION
Starting the engine
Ignition system
Periodic maintenance
Engine tUIlC- Up
Cylinde r block
Piston and piston rings
Engine
Flywheel and stator plate
Carburetor (Sportsman 500 H.G. models)
Cleaning and inspection
Carburetor tests and adjustments
Drive belt
Driv en pulley (200 3 models bui lt
afte r 07/08102)
INDEX .
WIRING DIAGRAMS .
.. . .. . . 382
Front master cylinder
Rear master cylinder
Brak e hose replacement
Rear brake peda l
Rem brake lever
( 1996 -1997 Sweden mod els)
Foot brak e
(199 8-on Sweden model s)
Brake d isc
Bleeding the sys tem
... .. .. .. . 425
Radiator guard
Rear rack
Rear fender
https://www.tradebit.coms
Rear bumper (mode ls so eq uipped)
... ... .... . 437
Transmission
Lighting system
Electrical components
Stee ring sha ll (2002-on mode ls)
Rear hub and bearing carrier (2003 mode ls)
Rear brake pad replacement
(2003 models)
Rear ca lipers (200 3 mod els)
Front master cylinder
Rear master cylinder (2003 models)
Rear brake disc (200 3 mode ls)
Brake hose replacemen t (2003 models)
PLUS MUCH, MUCH MORE!
This manual is very easy to use, it is designed in PDF format to simply view on your windows pc or mac/tablet/smartphones etc. You can print what you need when you need it and throw away when the work is complete. You can also print this entire manual if you would like to have a hardcopy.
The ONLY Workshop Service Manual You Will Ever Need.
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Tags:
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