Product Category:
All-Terrain Vehicle (ATV) Parts Manual
Target Audience:
Owners and technicians performing maintenance, repair, or parts replacement on the Polaris Magnum 500 2x4 HDS.
Visual Aid:
Comprehensive exploded views for precise component identification.
Accuracy:
Ensures correct part ordering, minimizing errors and downtime.
Usability:
Streamlines the process of identifying and sourcing necessary replacement parts.
Engine Assembly:
Exploded views and part numbers for engine components (carburetor, crankshaft, valves, etc.)
Drivetrain:
Components for 2x4 drive system, including transmission, gears, axles.
Suspension:
Front and rear suspension components, including forks, shocks, swingarms.
Brakes:
Brake system components, including rotors, pads, calipers, lines.
Electrical:
Components for lighting, ignition, charging system (magneto, stator, rectifier, battery).
Bodywork And Plastics:
Fenders, plastics, seat, handlebars, panels.
Fuel System:
Carburetor and fuel pump components, including jets, mixture screws.
Cooling System:
Radiator and coolant components.
Part Identification:
Identification of all part numbers and their locations via exploded views.
Assembly Relationship:
Demonstrates how components fit together in assemblies.
Part Ordering:
Facilitates accurate part ordering by providing specific part numbers.
Depth:
Detailed component-level information for parts identification and replacement.
Type:
Single-cylinder, 4-stroke, liquid-cooled
Displacement:
Approximately 499cc (actual displacement for Magnum 500 models)
Bore X Stroke:
Specifics not provided in product info, but typical for 499cc single cylinder
Compression Ratio:
Specifics not provided in product info.
Horsepower:
Estimated 30-35 HP (typical for this engine size and application)
Torque:
Specifics not provided in product info.
Carburetor:
Mikuni BSR42 (common for this model) - Manual covers carburetor components and jets (main, pilot, mixture screw).
Fuel Pump:
Manual covers fuel pump components.
System:
CDI (Capacitor Discharge Ignition), often with a magneto/stator.
Oil Type:
Manual may specify recommended oil viscosity and type for engine oil.
System:
Electric Start, Kickstart (manual covers starter motor, kickstart mechanism).
Length:
Specifics not provided in product info.
Width:
Specifics not provided in product info.
Dry Weight:
Specifics not provided in product info, but typically around 600-650 lbs for this model.
Towing Capacity:
Specifics not provided in product info.
Payload Capacity:
Specifics not provided in product info.
General:
While this manual is for parts, a full service manual would detail specific intervals for engine oil changes, filter replacements, brake fluid, etc. This parts manual is essential for obtaining the correct replacement parts for these services.
Engine Oil:
Manual may reference recommended SAE viscosity grades and API service classifications for engine oil.
Coolant:
Manual may reference coolant type and mixture ratios.
Brake Fluid:
Manual may reference DOT specifications for brake fluid.
Common Wear Items:
Brake pads, tires, carburetor jets, starter brushes are common wear items for ATVs of this era, all of which are covered by part numbers in this manual.
Part Identification For Repair:
Crucial for diagnosing and replacing faulty components such as ignition coils, fuel pumps, or drive train parts.
Manufacturer:
Polaris Industries, known for its extensive line of powersports vehicles.
Magnum Line:
The Magnum series was a popular line of utility and sport-utility ATVs from Polaris, known for their robust performance.
Model Years:
The Magnum 500 2x4 HDS was produced in the early 2000s, with 2002 being a specific model year.
