Description
Polaris 1996-2003 Sportsman 400500 & Xplorer 500 4×4 Service Repair Manual – PDF DOWNLOAD
FILE DETAILS:
Polaris 1996-2003 Sportsman 400500 & Xplorer 500 4×4 Service Repair Manual – PDF DOWNLOAD
Language : English
Pages : 504
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Polaris 1996-2003 Sportsman 400500 & Xplorer 500 4×4 Service Repair Manual – PDF DOWNLOAD
Introduction1
Chapter 1 – General Information7
Chapter 2 – Troubleshooting 42
Chapter 3 – Lubrication, Maintenance, & Tune-Up 59
Chapter 4 – Engine Top End100
Chapter 5 – Engine Lower End143
Chapter 6 – Fuel System181
Chapter 7 – Cooling System204
Chapter 8 – Clutch/Drive System219
Chapter 9 – Transmission255
Chapter 10 – Front Drive System296
Chapter 11 – Electrical System309
Chapter 12 – Front Suspension & Steering343
Chapter 13 – Rear Suspension368
Chapter 14 – Breaks388
Chapter 15 – Body431
Supplement443
INDEX476
WIRING DIAGRAMS482
DESCRIPTION:
Polaris 1996-2003 Sportsman 400500 & Xplorer 500 4×4 Service Repair Manual – PDF DOWNLOAD
SAFETY FIRST:
Professional mechanics can work for years and ever sustain a serious injury. If a few rules of com- mon sense and safety are observed, many safe hours an be enjoyed servicing the ATV. Ignoring these
rules can injure someone working on the vehicle, or damage the ATV.
1. Never use gasoline or any type of low flash point solvent to clean parts. See Cleaning Parts and Handling Gasoline Safely in this chapter for additional information on parts cleaning, gasoline use and safety.
2. Never smoke or use a torch in the vicinity of flammable liquids in open containers, such as gasoline or cleaning solvent.
3. If welding or brazing is required on the vehicle, remove the fuel tank, carburetor, and front and rear shocks to a safe distance at least 50 feet (15 m) away.
4. Use the proper sized wrenches to avoid damage to fasteners.
5. When loosening a tight or stuck nut, be guided by what would happen if the wrench slips.
6. When replacing a fastener, make sure to use one with the same measurements and strength as the old one. Incorrect or mismatched fasteners can result in damage to the vehicle and possible personal injury. Beware of fastener kits that are filled with cheap and poorly made nuts, bolts, washers and cotter pins. Refer to Fasteners in this chapter for addi- tional information.
7. Keep all hand and power tools in good condition. Wipe greasy and oily tools after using them. Dirty tools are difficult to hold and can cause injury. Re- place or repair worn or damaged tools.
8. Keep the work area clean and uncluttered.
9. Wear safety goggles during all operations in- volving drilling, grinding, the use of a cold chisel, using chemicals, cleaning parts, when using com- pressed air or anytime the safety of eyes is in- volved.
10. Make sure to wear the correct type of clothes for the job. Long hair should be tied up or covered with a cap so that it cannot be caught by a piece of moving equipment or tool.
G.B 05/04/25
