Target Audience:
Recreational riders, farmers, hunters, trail riders.
Competitors:
Yamaha Kodiak, Honda FourTrax, Kawasaki Bayou.
Engine Size:
Reputable 499cc liquid-cooled engine.
Drivetrain Capability:
True All-Wheel Drive (AWD) system, offering superior traction.
Suspension:
Independent front and rear suspension for a comfortable and capable ride.
Covered Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Covered Models:
Sportsman 500, Sportsman 500 RSE, Sportsman 500 HO, Xplorer 500
Type:
Factory Service Manual / Repair Manual
Engine:
Top End, Bottom End, Lubrication, Cooling, Fuel System, Ignition System, Starting System
Drivetrain:
Transmission, Final Drive, Drive Shafts, Axles, CV Joints, AWD System (where applicable)
Chassis:
Frame, Suspension (Front and Rear), Steering, Wheels, Tires
Electrical:
Wiring Diagrams, Lighting, Battery, Charging System, Ignition, Switches, Gauges
Braking:
Hydraulic Brake System, Brake Calipers, Master Cylinder, Lines, Pads, Rotors
Bodywork:
Body Panels, Racks, Fenders, Seat
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Points
Troubleshooting:
Diagnostic Procedures, Symptom-Based Troubleshooting Guides, Common Issues
Repair:
Component Removal and Installation, Engine Rebuild, Transmission Overhaul, Suspension Repair, Electrical Component Testing and Replacement
Tune Up:
Carburetor Adjustment, Spark Plug Service, Ignition Timing, Valve Adjustment (if applicable)
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and torque specifications.
Type:
4-stroke, SOHC, 4-valve, Single Cylinder
Bore X Stroke:
92 mm x 75 mm
Cooling System:
Liquid-cooled
Horsepower Est:
Approximately 28-32 HP (varies by specific model year and tuning)
Torque Est:
Approximately 29-32 lb-ft (varies by specific model year and tuning)
Carburetor:
Mikuni BNS 36 (specific model may vary, e.g., 40mm) with accelerator pump.
Fuel Type:
Unleaded gasoline, 87 octane minimum.
Type:
CDI (Capacitor Discharge Ignition)
Oil Type:
Polaris Premium 4-Stroke Synthetic Oil 0W-40 or SAE 10W-40 Motorcycle Oil (API SG or higher).
Oil Capacity:
Approx. 2.1 L (2.2 US qt) with filter change.
Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand True All-Wheel Drive (AWD) with 2WD selectable.
Clutch System:
Dual Clutch CVT with centrifugal clutch and variable drive/driven pulleys.
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant or SAE 10W-40 Motorcycle Oil.
Transmission Oil Capacity:
Approx. 0.5 L (0.5 US qt)
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm)
Wheelbase:
Approx. 50 inches (127 cm)
Dry Weight:
Approx. 540 lbs (245 kg)
Ground Clearance:
Approx. 8-10 inches (20.3-25.4 cm) depending on suspension setup.
Front Rack Capacity:
Approx. 50 lbs (22.7 kg)
Rear Rack Capacity:
Approx. 100 lbs (45.4 kg)
Atv Safety:
Designed for off-road use; operator must follow all safety precautions outlined in the owner's manual and recommended by Polaris.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Hand-lever actuated parking brake.
Throttle Limiter:
Adjustable throttle stop for novice riders.
Lighting:
Dual Halogen headlights, taillight/brake light.
Gauge Cluster:
Digital speedometer/odometer, neutral/reverse indicators, fuel gauge (on some models), high-beam indicator, oil light.
Drivetrain Control:
On-Demand AWD system automatically engages front drive when rear wheels lose traction.
Accessories:
Pre-wired for accessories like winches, lights, and heated grips on some models.
Oil Change:
Every 100 hours or 12 months. Check dipstick more frequently.
Air Filter:
Inspect every 20 hours; clean or replace as needed, more frequently in dusty conditions.
Spark Plug:
Replace every 100 hours or 12 months. Check gap at 20 hours.
Valve Adjustment:
Check every 100 hours or 12 months.
Brake Fluid Flush:
Recommended every 12 months or as needed.
Coolant:
Ethylene glycol-based antifreeze mixed 50/50 with distilled water. Polaris Coolant is recommended.
Common Wear Items:
Drive belts (CVT), wheel bearings, ball joints, tie rod ends, brake pads.
Engine Variations:
Early models may have had some carburetor jetting or ignition timing differences compared to later HO (High Output) versions.
Cv Boots:
Susceptible to tearing in rough terrain; regular inspection is advised.
Manufacturer:
Polaris Industries, founded in 1954, a major American manufacturer of powersports vehicles.
Lineage:
The Sportsman line is Polaris's flagship ATV series, known for utility and off-road capability. The 500cc engine was a popular choice for this platform throughout the late 90s and early 2000s.
Manufacturing Location:
Primarily manufactured in the United States (e.g., Roseau, Minnesota).
