Target User:
Polaris Explorer 500 owners, independent repair shops, and enthusiasts seeking to maintain or repair their vehicle
Value Proposition:
Provides essential technical data for effective DIY repairs and maintenance, potentially saving significant costs compared to professional servicing
Manual Purpose:
Empowers users with the knowledge to perform repairs, prevent future issues, and understand their vehicle's inner workings
Delivery Method:
Instant download via email, eliminating shipping costs and wait times
Problem Prevention:
Emphasizes preventative maintenance to extend the lifespan of the vehicle and reduce the likelihood of costly repairs.
Main Coverage:
Service, Repair, Maintenance, Troubleshooting
Specific Sections:
General Information, Troubleshooting, Lubrication, Maintenance and Tune-up, Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, Body, Wiring Diagrams, Index
Estimated Page Count:
Varies based on original factory publication, typically 300-600+ pages for comprehensive coverage
Type:
Service Repair Manual / Workshop Manual
Digital Format:
PDF / WINRAR
Powertrain:
Engine (top and lower end), Fuel System, Cooling Systems, Transmission, Clutch/Drive Belt System, Front Drive System
Chassis And Suspension:
Front Suspension and Steering, Rear Suspension, Brakes
Electrical And Body:
Electrical System, Wiring Diagrams, Body
Fuel And Exhaust:
Fuel tank, fuel lines, fuel pump (if applicable), carburetor assembly, exhaust system components
Lubrication System:
Oil injection system (if applicable), oil tank, oil pump, lubrication points
Body And Chassis:
Body panels, fenders, seat, handlebars, frame integrity, mounting hardware
Maintenance And Tune Up:
Scheduled maintenance, tune-up procedures, fluid level checks and changes, filter replacement
Troubleshooting And Diagnostics:
System-specific troubleshooting charts, diagnostic procedures, common problem identification
Repair And Rebuild:
Detailed disassembly, inspection, repair, and reassembly procedures for major components and systems
Engine Overhaul:
Piston and ring replacement, cylinder head service, crankshaft and bearing inspection and replacement, valve adjustments (if applicable to 2-stroke ports)
Drivetrain Maintenance:
CVT belt inspection and replacement, clutch service, gearcase oil changes, driveshaft and U-joint checks
Electrical Diagnostics:
Battery testing, charging system (stator, regulator/rectifier), starter motor operation, ignition system troubleshooting, lighting circuits
Suspension And Steering Service:
Shock absorber inspection and replacement, control arm bushing replacement, tie rod end service, steering post maintenance
Wiring Repair:
Detailed wiring diagrams are provided, facilitating diagnosis and repair of electrical faults. Includes wire colors and component locations.
Depth Of Coverage:
Comprehensive, covering from basic maintenance and troubleshooting to in-depth engine and transmission rebuilds
Diagnostic Tools:
While not explicitly detailing electronic diagnostic tools, it provides systematic troubleshooting steps that can be performed with basic hand tools and a multimeter.
File Types:
PDF (for viewing/printing), WINRAR (for compression/extraction)
Compatibility:
Windows (95/98/ME/XP/vista/7/8), Linux, MAC, iOS, Android - highly versatile for modern devices
Digital Quality:
High-resolution scans or digitally rendered content, ensuring clarity of text and diagrams
Digital Format:
N/A (Digital Download)
Digital Format:
N/A (Digital Download)
Engine Type:
Two-stroke, Twin-cylinder (typical for this era of Polaris ATVs)
Displacement:
Approximately 499cc (as indicated by model name)
Horsepower Estimate:
Typically in the range of 30-40 HP (subject to specific tuning and condition)
Carburetion:
Twin carburetors (likely Mikuni or Keihin, specific model depends on OEM spec)
Fuel Type:
Unleaded gasoline (87-octane or higher recommended)
Fuel Delivery:
Carbureted with possible oil injection for pre-mixing fuel and oil
Oil Mixture:
Two-stroke oil and gasoline mixture (specific ratio detailed in manual)
Cooling Method:
Liquid-cooled (typical for higher performance ATVs of this era)
Aspiration:
Naturally Aspirated
Transmission Type:
Automatic Continuously Variable Transmission (CVT) with engine braking
Gear Selection:
High, Low, Neutral, Reverse (selectable via shifter)
Drive System:
Shaft drive to rear axle, with selectable 2WD/4WD via front drive system
Transmission Fluid:
Specific CVT fluid or SAE 30/10W-30 transmission oil (refer to manual for exact specification and capacity)
Atv Safety Considerations:
Emphasis on proper operation, rider training, and adherence to safety gear recommendations (e.g., helmets, protective clothing)
Braking System:
Hydraulic disc brakes (typically front and rear, specific configuration detailed in manual)
Frame Construction:
Steel frame for durability and rigidity
Oil Change Interval:
Typically every 20-40 hours of operation or annually (refer to manual for exact specification)
Spark Plug Replacement:
Recommended at 100-200 hours or annually
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water recommended)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type)
Engine Oil Type:
2-stroke oil (specific API classification and viscosity grade will be detailed in the manual)
Common Wear Items:
Drive belt wear, carburetor gumming, starter solenoid issues, rear suspension bushings
Electrical Quirks:
Wiring harness fatigue, intermittent switch failures, corrosion on connectors are common in older ATVs and likely addressed in troubleshooting sections.
Ignition System:
Spark plug, ignition coil, CDI unit (troubleshooting covered in manual)
Polaris History:
Polaris Industries is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles, known for innovation and off-road capability.
Explorer Series:
The Explorer series represented Polaris's mid-range to entry-level ATV offerings, often focused on utility and recreational riding.
Production Period:
The Polaris Explorer 500 was a model within the 1990s lineup of Polaris ATVs.
