1996-2003 Polaris Sportsman 500 ATV manual

Product Information

Table of Contents

Chapter One: General Information

• Manual organization
• Notes, cautions and warnings
• Safety first
• Consumer information
• Reporting safety defects
• Maintenance schedule
• Service specifications
• Tools
• Torques
• Threaded-joining compounds
• Warnings
• Safety

Chapter Two: Troubleshooting

• Troubleshooting
• Engine troubleshooting
  • Diagnosis charts
  • Starting
  • Hard starting
  • Running
  • Engine misses or lacks power
  • Engine stalls
  • Excessive vibration
  • Engine overheats
  • Excessive noise
  • Engine loses compression
  • Engine backfires

Chapter Three: Lubrication, Maintenance and Tune-up

• Pre-ride check list
• Tires and wheels
• Battery
• Battery electrolyte cable connections
• Periodic maintenance
• Engine lubrication
• Tune-up

Chapter Four: Engine Top End

• Engine
• Cylinder head
• Cylinder head components
• Engine valve train components
• Rocker arm assembly
• Rocker arm procedure

Chapter Five: Engine Lower End

• Engine
• Short block
• Oil pump
• Crankshaft
• Crankshaft main bearing
• Piston and rings
• Connecting rod
• Connecting rod bearing
• Camshaft

Chapter Six: Fuel System

• Carburetor
• Fuel tank
• Fuel valve
• Fuel line
• Fuel pump
• Fuel injection (EFI models)
• Throttle control
• Throttle adjustment
• Fuel delivery system
• Engine air intake

Chapter Seven: Cooling System

• Cooling system
• Radiator
• Thermostat
• Cooling system inspection
• Radiator hose replacement
• Water pump
• Temperature sensors

Chapter Eight: Clutch/Drive Belt System

• Drive pulley
• Drive pulley removal
• Clutch outer and inner cover
• Drive belt

Chapter Nine: Transmission

• Transmission
• Transmission removal and installation
• Shift lever mechanism
• Transmission gearcase oil and level

Chapter Ten: Front Drive System

• Front axles and shafts
• Front axles and CV joints
• Front differential assembly
• Front differential oil

Chapter Eleven: Electrical System

• Electric starting system
• Electric ignition system
• Charging system
• Battery
• Fuse panel
• Ignition switch
• Spark plugs
• Wiring diagrams

Chapter Twelve: Front Suspension and Steering

• Front shock
• Steering
• Steering knuckle
• A-arms
• A-arm removal and installation
• Tie rods
• Tie rod adjustment

Chapter Thirteen: Rear Suspension

• Rear shock
• Rear shock removal and installation
• Rear A-arm
• A-arm removal and installation
• A-arm bearing
• Rear sway bar
• Rear sway bar bushing
• Rear sway bar removal and installation

Chapter Fourteen: Brakes

• Brakes
• Front brakes
• Front brake master cylinder
• Front brake pads replacement
• Rear brakes
• Rear brake master cylinder
• Rear brake pads replacement
• Front brake caliper
• Rear brake caliper
• Brake line bleeding
• Parking brake

Chapter Fifteen: Body

• Body
• Front rack and grille
• Foot well
• Seat
• Body panels
• Bumper (models so equipped)
• Rear rack
• Rear bumper (models so equipped)

Supplement: 2000-2003 Service Information

• Updates
• Transmission
• Electrical system
• Fuel system
• Cooling system
• Front drive system
• Engine (2000 models)
• Carburetor and intake manifold
• Fuel pump (2000 models)
• Cylinder head and components
• Ignition system (2000 models)
• Crankshaft (2000 models)
• Crankshaft main bearing (2000 models)
• Piston and rings (2000 models)
• Connecting rod (2000 models)
• Connecting rod bearing (2000 models)
• Camshaft (2000 models)
• Clutch/Drive Belt System (2000 models)
• Transmission gearcase oil and level (2000 models)
• Front axles and shafts (2000 models)
• Front axles and CV joints (2000 models)
• Front differential assembly (2000 models)
• Front differential oil (2000 models)
• Electric starting system (2000 models)
• Electric ignition system (2000 models)
• Charging system (2000 models)
• Battery (2000 models)
• Fuse panel (2000 models)
• Ignition switch (2000 models)
• Spark plugs (2000 models)
• Wiring diagrams (2000 models)
• Front shock (2000 models)
• Steering (2000 models)
• Steering knuckle (2000 models)
• A-arms (2000 models)
• A-arm removal and installation (2000 models)
• Tie rods (2000 models)
• Tie rod adjustment (2000 models)
• Rear shock (2000 models)
• Rear shock removal and installation (2000 models)
• Rear A-arm (2000 models)
• A-arm removal and installation (2000 models)
• A-arm bearing (2000 models)
• Rear sway bar (2000 models)
• Rear sway bar bushing (2000 models)
• Rear sway bar removal and installation (2000 models)
• Brakes (2000 models)
• Front brakes (2000 models)
• Front brake master cylinder (2000 models)
• Front brake pads replacement (2000 models)
• Rear brakes (2000 models)
• Rear brake master cylinder (2000 models)
• Rear brake pads replacement (2000 models)
• Front brake caliper (2000 models)
• Rear brake caliper (2000 models)
• Brake line bleeding (2000 models)
• Parking brake (2000 models)
• Body (2000 models)
• Front rack and grille (2000 models)
• Foot well (2000 models)
• Seat (2000 models)
• Body panels (2000 models)
• Bumper (2000 models)
• Rear rack (2000 models)
• Rear bumper (2000 models)

Index

Wiring Diagrams

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