Polaris Sportsman 500 1999-2003 Workshop Service Repair Manual

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The Polaris Sportsman 500, produced from 1999 to 2003, is a versatile utility All-Terrain Vehicle (ATV) powered by a 500cc liquid-cooled engine. This model is recognized for its Independent Front...

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Taper: Atv

Distributeur:

UGS: 156099

Mots clés: 1999 2000 2001 2002 2003 Agriculture Atv Commando Series Polaris Same Sportsman 500 Tractors

Variantes de produits

Description

The Polaris Sportsman 500, produced from 1999 to 2003, is a versatile utility All-Terrain Vehicle (ATV) powered by a 500cc liquid-cooled engine. This model is recognized for its Independent Front Suspension (IFS), providing enhanced ride quality and handling, and features shaft drive with On-Demand All-Wheel Drive (AWD) for superior traction. Its robust engineering and reliable performance made it a competitive choice in the 500cc ATV class, suitable for both work and recreational activities. This comprehensive workshop service repair manual in English details the repair, maintenance, and troubleshooting of the Polaris Sportsman 500. Covering all major systems including engine, drivetrain, chassis, and electrical components, it provides step-by-step instructions for disassembly, assembly, adjustments, and routine maintenance. The manual also includes detailed technical specifications, torque values, wear limits, and electrical wiring diagrams, serving as an essential resource for owners and technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Applicable Model Years:

1999, 2000, 2001, 2002, 2003

Codes

Engine Code General:

500cc OHV 4-stroke

👋 Introduction

Market Position

Category:

Utility All-Terrain Vehicle (ATV)

Competitive Analysis

Comparison Vehicles:

Competed against other 500cc class ATVs from manufacturers like Yamaha (Kodiak), Honda (FourTrax Foreman), and Suzuki (King Quad) during its production run. Known for its Polaris Independent Front Suspension (IFS) and robust engine.

Key Features

Signature Features:

Polaris Independent Front Suspension (IFS) for improved ride quality and handling, Shaft Drive, Liquid-Cooled engine, High/Low range transmission, On-Demand AWD.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, maintenance, troubleshooting, adjustments, and disassembly/assembly of the Polaris Sportsman 500 (1999-2003 models).

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine removal and installation, internal engine components (cylinder, piston, crankshaft, camshaft), lubrication system, cooling system (if applicable, though typically air-cooled), fuel system (carburetor, fuel lines), ignition system, starting system, exhaust system.

Drivetrain Systems:

Transmission (gearbox), final drive, drive shafts, CV joints, differential (if applicable), AWD system components.

Chassis Systems:

Frame, suspension (front and rear), steering system, brakes (hydraulic lines, calipers, master cylinder, pads), wheels, tires.

Electrical Systems:

Battery, charging system (stator, regulator/rectifier), lighting, instrumentation, starter motor, wiring diagrams, switches, sensors.

Bodywork And Accessories:

Body panels, racks, seat, controls, decals, accessories installation.

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, spark plug service, chain/belt adjustments, lubrication points.

Troubleshooting:

Systematic diagnostic procedures for common and complex issues, fault finding guides, symptom-based troubleshooting.

Repair And Rebuild:

Step-by-step instructions for disassembly, cleaning, inspection, repair, and reassembly of all major components and systems.

Adjustments:

Carburetor adjustment, valve clearance adjustment, brake adjustment, steering alignment checks.

Special Tools And Equipment:

Identification and usage instructions for specialized tools required for specific repair operations.

Wiring Diagrams:

Detailed electrical wiring diagrams provided for all systems.

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine rebuilds and system diagnostics, including detailed torque specifications, wear limits, and electrical schematics.

Specifications Coverage:

Includes crucial technical specifications such as torque values, clearance measurements, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

File Type:

Searchability:

PDF format with searchable text for efficient information retrieval.

Print Quality

Printability:

High-quality, fully printable on all pages.

Binding Type

Binding:

Digital (PDF Download), suitable for printing and binding.

Paper Type

Paper Type Recommendation:

Standard printer paper, with heavier stock recommended for frequently referenced pages if printing a physical copy.

Requirements

Software Requirement:

Adobe Reader (or compatible PDF viewer)

Compatibility

Operating Systems:

Windows, macOS, Linux

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve

Displacement:

499cc (approx.)

Bore X Stroke:

92.0 mm x 75.0 mm (typical for this engine family)

Cooling System:

Liquid-Cooled

Performance

Horsepower Approx:

30-35 HP (estimated at peak)

Torque Approx:

30-35 ft-lbs (estimated at peak)

Fuel System

Carburetor:

Mikuni BSR42 (typical, specific jetting may vary)

Fuel Type:

Unleaded gasoline (87 octane or higher)

Engine Oil

Oil Type Recommendation:

SAE 10W-40 or SAE 20W-50, API SG or higher

Oil Capacity With Filter:

Approx. 2.5 quarts (2.36 liters) - always verify with dipstick

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Drive System:

Shaft Drive, On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector.

Fluid Specs

Cvtf Fluid Type:

Polaris Variable Transmission Fluid (PVT) or equivalent CVT fluid.

📐 Dimensions

Exterior

Length:

83.5 inches (212.1 cm)

Width:

46 inches (116.8 cm)

Height:

47 inches (119.4 cm)

Weights

Dry Weight:

Approx. 650 lbs (295 kg)

Towing Capacity:

1500 lbs (680 kg)

Cargo Capacity Rear Rack:

100 lbs (45 kg)

Cargo Capacity Front Rack:

50 lbs (23 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Manufactured to meet ANSI/SVIA standards.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Rollover Protection:

N/A (Standard ATV design, operator must exercise caution).

💡 Technology Features

Infotainment

Audio System:

N/A (Not equipped with standard infotainment system).

Driver Assistance

Traction Control:

Cruise Control:

Connectivity

Bluetooth:

Instrumentation

Dashboard Features:

Speedometer, Odometer, Tripmeter, Fuel Gauge, Gear Position Indicator, AWD Indicator Light, Neutral Indicator Light, High Temperature Warning Light.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first.

Spark Plug Replacement:

Every 100 hours or annually.

Air Filter Cleaning:

Every 50 hours or more frequently in dusty conditions.

Cv Belt Inspection:

Every 50 hours, check for wear and damage.

Valve Clearance Check:

Every 100 hours or annually.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Type:

Proprietary Polaris Coolant or a mixture of ethylene glycol and distilled water (50/50 mix).

Known Issues

Common Wear Items:

CV joint boots, brake pads, suspension bushings, battery, starter solenoid.

Carburetor Issues:

Clogged jets due to fuel varnish if not run regularly or stale fuel, requiring cleaning or rebuilding.

Cv Belt Slippage:

Can occur with excessive heat, wear, or incorrect tension, leading to loss of power and acceleration.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Polaris Industries, founded in 1954, Roseau, Minnesota, USA. Initially known for snowmobiles, expanded into ATVs in the late 1980s.

Model Evolution

Development:

The Sportsman line represented Polaris's entry into the premium utility ATV market. The 500cc engine became a popular and reliable powerplant, evolving through various iterations including the 'H.O.' (High Output) versions in later years.

Production

Manufacturing Location:

Roseau, Minnesota, USA (primary).

🏆 Awards & Recognition

Recognitions

General Reputation:

Widely regarded as a reliable and capable workhorse ATV during its era, contributing to Polaris's market share growth.

Certifications

Manufacturing Certification:

ISO 9001 certified manufacturing processes (typical for Polaris during this period).