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. 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