Polaris Sportsman Xplorer 500 Atv Workshop Service Repair Manual 1996-2003 # 1 Download (PS028413)

Polaris Sportsman Xplorer 500 Atv Workshop Service Repair Manual 1996-2003 # 1 Download (PS028413)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• Polaris Sportsman Xplorer 500 ATV Workshop Service Repair Manual 1996-2003

  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 H.O.Freedom
  
  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
  
  Footv..ells
  
  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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