Polaris Sportsman Xplorer 500 ATV Workshop Service Repair Manual 1996-2003 1 Download PDF

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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...

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UGS: 42784

Mots clés: Atv Manual Polaris Repair Guide

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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 ...
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