1996–2006 Polaris Sportsman 500 DUSE HO Service Manual (P/N 9913680, 9914752)

This 633-page PDF combines the Polaris 1996-1998 ATV and Light Utility Vehicle Service Manual Volume II, P/N 9913680, with the 1998 Service Manual Update, P/N 9914752. Coverage is much broader than a Sportsman 500-only book: it spans multiple Gen II, III, and IV chassis, 2x4, 4x4, and 6x6 layouts, chain- and shaft-drive systems, and both two-stroke and four-stroke engines. Polaris designed the manual primarily for ATV service technicians in a properly equipped shop and states that service work should be performed by qualified personnel with knowledge of mechanical theory, tools, and shop procedures.

• Identifies the covered model-year configurations, VIN and model-number formats, engine and transmission identification points, Gen II/III/IV body styles, routing details, and year-specific service bulletin applications.
• Covers EC25PF, EC28PF, and EC38PL two-stroke engine repair, including removal, disassembly, crankshaft alignment, oil-pump end-play adjustment, check-valve testing, inspection, assembly, and troubleshooting.
• Documents EH42PL and EH50PL four-stroke service through engine removal and installation, internal disassembly and inspection, valve and cam timing work, crankshaft installation, water-pump seal replacement, assembly, and fault diagnosis.
• Details Mikuni VM and BST/CV carburetor theory, altitude-and-temperature jetting charts, fuel-flow diagnosis, carburetor removal and overhaul, needle-and-seat pressure testing, fuel-pump vacuum testing, and model-specific adjustment data.
• Handles PVT drive and driven clutch repair, belt and offset checks, bushing replacement, Engine Braking System service, internal repair of Type III EZ Shift and Type IV shaft-drive transmissions, and Type V transmission removal for 1998 Scrambler models.
• Provides Demand 4 and Hilliard front-hub service, axle and U-joint repair, 6x6 sprocket and eccentric work, suspension and Fox shock service, hydraulic brake bleeding and caliper overhaul, plus ignition, charging, starter, speed-limiter, ETC, and AWD electrical testing.

Model and Configuration Coverage

The annual tables cover Trail Boss and Trail Blazer models; Xpress and Xplorer 300; Sport/Sport 400; Scrambler 4x4, 400, and 500; Xpress 400 for 1996-1997; Xplorer 400; Sportsman 4x4/400L and Sportsman 500; Magnum 2x4, 4x4, and 6x6; and the 400 6x6. They also identify the 1997 Xplorer 500 and the 1998 Big Boss 500 6x6. Sportsman 500 information is included for all three model years. Year-specific material separates the 1998 Scrambler 400/500 Type V transmission and the dual-hydraulic rear brake used on those machines and the 1998 Sportsman 500.

Specifications and Shop Procedures

Maintenance content includes periodic service schedules, approved lubricants and fluid capacities, two-stroke oil-pump adjustment and bleeding, four-stroke valve-clearance work, coolant pressure testing, compression and cylinder-leakage checks, drive-chain adjustment, toe alignment, and brake-fluid replacement. Reference tables supply engine, carburetor, clutching, gear-ratio, electrical, torque, clearance, wear-limit, and component-identification data.

Special-tool callouts include the Mity Vac pump kit (P/N 2870975) for cooling, carburetor-seat, and oil-system tests; the drive clutch puller (P/N 2870506) and clutch bushing kit (P/N 2871226); the shaft-drive transmission tool kit (P/N 2871702); and the Tektronix DMM 155 (P/N 2870659).

Diagrams, Testing, and Repair Cautions

Named visual references include the EH42PL/EH50PL oil-flow chart, Gen II/III/IV fuel-tank exploded views, Mikuni VM and BST carburetor exploded views, the Demand 4 front-hub view, the Type IV shaft-drive transmission exploded view, and model-specific wiring diagrams for 1996, 1997, and 1998. Factory routing plates show Magnum wiring, fuel, coolant, and brake lines; 300 fan-motor wiring; Sportsman 500 oil-tank vent routing; and all-model engine-wire placement. Electrical sections add ignition timing curves, alternator views, component-location photos, resistance specifications, and test charts for charging, starting, speed-limiter, switch, and AWD circuits.

The four-stroke assembly section flags cam-to-crank timing errors that can cause serious internal engine damage. The EBS chapter also identifies the one-way clutch seals as vulnerable during driven-clutch disassembly. Exploded views support component identification, but the manual directs parts ordering to the applicable model-specific parts book; this PDF is a service publication, not a replacement parts catalog.

Note: Always observe standard shop safety protocols and verify the exact vehicle configuration, approved fluid type, and component-specific torque requirements before beginning diagnostic or repair work.