POLARIS SPORTSMAN XPLORER 500 ATV 1996 1997 1998 1999 2000 2001 2002 2003 FACTORY SERVICE MANUAL
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POLARIS SPORTSMAN XPLORER 500 ATV 1996 1997 1998 1999 2000 2001 2002 2003 FACTORY SERVICE MANUAL
This detailed. comprehensive manual covers the Polaris Sportsman 400, 500 and Xp lorer 500 4 x 4 from I 996-on. Keep this book hand y in the toolbox. Readin g and using it will help to better understand how the vehicle runs, lower repair cos ts and generally improve personal satisfaction with the vehicle. The following tables are included at the end of this chapter:
Tahle 1 lists model year and number.
Tahle 2 lists general dimensions .
Ta ble 3 lists vehicle weight (dry) .
Table 4 lists decimal and metric equivalents.
Tab le 5 lists general torque specifications.
Tab le 6 lists conversion tables .
Ta ble 7 lists technical abbreviations.
Table 8 lists metric tap and drill sizes.
Tables 1-8 are at the end of this chapter.
MANUAL ORGANIZATION:
All dimensions and capacities are express d in English units familiar to U.S. mechanics. as well as in metric units. This chapter provides general information and discusses equipment and too ls useful both for preventive maintenance and troubleshooting. Chapter Two provides methods and suggestions for the quick and accurate diagnosis and repair of problems. Troubleshooting procedures discuss typ2ical symptoms and logi cal methods to pinpoint the trouble. Chapter Three explains all periodic lubrication and routine maintenance necessary to keep the vehicle funn ing well. Chapter Three also includes recommended tUIl C-Up procedures , eliminating the need to constantly consult chapters on the various assemblies .
- Subsequent chapters describe specific systems such as the engine, clutch/drive belt system, transmission, exhaust, coo ling, suspension and brakes. Each chapter provides disassembly, repair and assembly procedures in a simple step- by-step form. If a repair is impractical for a home mechanic.
- It is so indicated. It is usually fasteramiless expensive to take such repairs to a dealer or competent repair shop. Specifications concerning a particular system arc included at the end of the appropriate chapter. Some of the procedures in this manual specify special tools. In most cases, the too l is illustrated either in actual use or alone. We ll-e quipped mechanic s may find they ca n substitute similar tools already on hand or ca n fabricate their own.
TABLE OF CONTENTS:
POLARIS SPORTSMAN XPLORER 500 ATV 1996 1997 1998 1999 2000 2001 2002 2003 FACTORY SERVICE MANUAL
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
Fasteners
Lubricants
Thread locking compound
RTV gasket sealant
CHAPTER TWO
TROUBLESHOOTING
Operation g requirement s
Troubleshooting instruments
Starting the engine
Starting difficulties
Engine is difficult to start
Engine starting system
Charging system
Ignition system
Electronic throttle control
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 36
Fuel system
Engine overheating
Engine
Engine noises
Cylinder leak down test
Power train
Steering
Frame noise
Brakes
CHAPTER THREE
LUBRICATION, MAINTENANCE AND TUNE-UP
Preride check list
Tire s and whee ls
Battery
Battery electrical cable connectors
Periodic lubrication
CHAPTER FOUR .
ENGINE TOP END
Engine principles
Engine cooling
Engine lubrication
Servicing the engine in the frame
Exhaust system
Cylinder head cover
Rocker ann assembly
CHAPTER FIVE
ENGINE LOWER END
Engine
Flywheel and startor plate
Recoil starter
Crankcase
Crankshaft inspection
Balancer shaft inspection
CHAPTER SIX
FUEL SYSTEM
Carburetor operation
Carburetor
Carburetor cleaning and inspection
Carburetor tests and adjustments
Throttle cable replacement
CHAPTER SEVEN
COOLING SYSTEMS
Polaris variable transmission (PVT)
air cooling system
Engine cooling system
Safety precautions
Hoses and hose clamps
Engine gaskets/sea ls 53
Periodic maintenance
Unscheduled inspection
and maintenance
Engine tune-up 94
Camshaft
Cylinder head
Valves and valve components
Cylinder block
Piston and piston rings
Camshaft chain and sprockets
Break-in procedure 137
Shan end float measurement
and shim select ion
Oil pump
Oil system one-way c heck valve
Break -in procedure 175
Stalling enrichment (choke) cable
Fuel tank
Fuel shutoff valve
Air filter air box
Fuel pump 198
Coo ling system inspect ion
Radiator
Cooling fan
Coolant pump
Thermostat
Temperature sensors
CHAPTER EIGHT .
CLUTCH/DRIVE BELT SYSTEM
Drive unit
Drive pulley
Special 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 information
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
Rear axles
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 drive shaft
Front drive unit 303
Electric starting system
Starter drive gears
Starter solenoid
Lighting system
Electrical components
Switches
Wiring diagrams 337
Handlebar
Tie rods
Steering 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 pad replacement
Front caliper
Output shaft brake pad replacement
(1996-1997 mode ls)
Output shall brake caliper
( ]996- 1997 mode ls)
Output shall brake pad replacement
( 1998- 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
Cylinder 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
Driven pulley (200 3 models built
after 07/08102)
INDEX .
WIRING DIAGRAMS 382
Front master cylinder
Rear master cylinder
Brake hose replacement
Rear brake pedal
Rem brake lever
( 1996 -1997 Sweden models)
Foot brake
(199 8-on Sweden model s)
Brake disc
Bleeding the system 425
Radiator guard
Rear rack
Rear fender
Footvells
Rear bumper (mode ls so equipped) 437
Transmission
Lighting system
Electrical components
Steering shall (2002-on mode ls)
Rear hub and bearing carrier (2003 mode ls)
Rear brake pad replacement
(2003 models)
Rear calipers (200 3 models)
Front master cylinder
Rear master cylinder (2003 models)
Rear brake disc (200 3 mode ls)
Brake hose replacement (2003 models)
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