Target Audience:
Owners of the 1997 Polaris ATV Explorer 500, professional mechanics, and DIY enthusiasts seeking to maintain, diagnose, and repair their vehicle.
Value Proposition:
Provides comprehensive, factory-level repair and maintenance information, empowering users to perform tasks effectively and reduce reliance on external service centers.
Manual Features:
Includes detailed diagrams, exploded views, specifications, troubleshooting guides, and step-by-step procedures.
Completeness:
Covers all major systems of the vehicle, offering a complete guide to ownership and maintenance.
Covered Systems:
General Information, Troubleshooting, Lubrication, Maintenance, 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:
Likely 300-500 pages (typical for a comprehensive workshop manual of this era).
Type:
Workshop Repair Manual / Service Manual
Engine:
Complete coverage from top-end components (cylinder head, valves, camshaft) to lower-end assemblies (crankshaft, connecting rods, pistons), including disassembly, inspection, rebuilding, and assembly procedures.
Fuel System:
Detailed information on the carburetor (likely a Mikuni VM series), fuel pump, fuel lines, and fuel tank servicing.
Cooling System:
Covers radiator, fan, coolant hoses, thermostat, and related components for the liquid-cooled engine.
Drivetrain:
Includes clutch/drive belt system (primary and secondary clutches), transmission (gearbox), and front drive system (CVT, driveshafts, differentials).
Electrical System:
Comprehensive coverage including battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plug), lighting, starter motor, and basic wiring diagnostics.
Suspension Steering:
Detailed procedures for front and rear suspension components, including shocks, springs, A-arms, bushings, and steering system components (handlebars, tie rods, steering shaft).
Brakes:
Covers hydraulic brake systems, including master cylinders, calipers, brake lines, brake pads, and levers/pedals. Likely also covers parking brake mechanism.
Body:
Information related to body panels, fenders, racks, and potentially seat removal/installation.
Maintenance:
Regular maintenance tasks such as oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, and general inspections.
Troubleshooting:
Systematic diagnostic procedures to identify and resolve common problems, with flowcharts and symptom-based solutions.
Repair:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major vehicle systems.
Tune Up:
Procedures for setting ignition timing (if applicable, though often fixed on CDI systems), carburetor adjustments, and general engine tuning for optimal performance.
Rebuilding:
Detailed guidance on rebuilding engine components, transmission, and potentially brake master cylinders or calipers.
Depth Level:
Comprehensive. Designed for both beginner mechanics and experienced technicians, covering basic maintenance to complete engine and component overhauls.
Diagnostic Capabilities:
Advanced diagnostic information, including troubleshooting charts, electrical schematics, and specifications for diagnosing performance issues.
Digital Format:
PDF (Portable Document Format) and WINZIP (compressed archive). Compatible with any device capable of reading PDFs, across all major operating systems.
Printability:
Printable pages, allowing users to create a physical copy for workshop use.
Binding Type Physical Equivalent:
Digital (no physical binding).
Paper Type Physical Equivalent:
Digital (no physical paper type).
Text Search:
Likely searchable text within the PDF for quick information retrieval.
Instant Download:
Yes, instant download via email with no waiting time.
Engine Type:
Four-stroke, liquid-cooled, SOHC (Single Overhead Camshaft)
Displacement:
499 cc (Cubic Centimeters)
Bore X Stroke:
Information typically found within the manual's engine section, likely around 92 mm x 73 mm.
Compression Ratio:
Typically around 9.0:1 to 10.0:1 for this era of 4-stroke ATV engines.
Horsepower:
Estimated to be in the range of 25-30 HP (Horsepower), though exact figure would be in the manual.
Torque:
Specific torque figures for peak output would be detailed in the manual.
Carburetor Model:
Likely a Mikuni VM36 or similar constant-velocity carburetor.
Fuel Type:
Unleaded gasoline
Cooling Method:
Liquid-cooled
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft drive to rear differential, likely with an option for 4WD engagement via a lever or electronic switch.
Clutch System:
Primary and secondary CVT clutches, with detailed maintenance and adjustment procedures in the manual.
Gear Reduction:
Information on internal gear reduction ratios for forward and reverse would be in the manual.
Transmission Fluid Type:
Likely a specific CVT fluid or a high-quality SAE 10W-30 or 10W-40 engine oil. Manual will specify exact type and capacity.
Length:
Approximately 81.5 inches (2070 mm) - typical for this class of ATV.
Width:
Approximately 43 inches (1092 mm) - typical.
Height:
Approximately 44 inches (1118 mm) - typical.
Dry Weight:
Around 550-600 lbs (250-272 kg) - typical for a 500cc ATV of this era.
Ground Clearance:
Likely 8-10 inches (203-254 mm).
Rack Capacity Front:
Information not explicitly stated, but typically around 50-75 lbs.
Rack Capacity Rear:
Information not explicitly stated, but typically around 100-150 lbs.
Safety Standards:
Designed to meet industry standards for ATVs of its time. Specific certifications would not be typical for this product category.
Braking System:
Hydraulic disc brakes on all wheels.
Lighting:
Headlights, taillight, and brake light for visibility.
Chassis Design:
Sturdy frame construction providing a stable platform.
Ergonomics:
Designed for rider control and comfort during operation.
Oil Change Interval:
Typically every 100 hours or 6 months, but the manual will provide precise intervals based on usage.
Air Filter Maintenance:
Regular cleaning/replacement recommended, especially in dusty conditions. Intervals will be specified.
Spark Plug Check:
Recommended at regular intervals (e.g., every 50-100 hours) for optimal performance.
Engine Oil Type:
Likely SAE 10W-30 or 10W-40 API SG or higher. Manual to confirm specific grade and capacity (approx. 2-2.5 quarts).
Coolant Type:
Ethylene glycol-based antifreeze mixture. Manual to specify concentration and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual to specify exact type and reservoir capacity.
Common Wear Items:
CVT belt wear, shock absorber performance degradation, bushings in suspension components, and potential carburetor tuning issues over time.
Electrical Reliability:
Early Polaris models could sometimes exhibit minor electrical issues; the manual's troubleshooting section is crucial here.
Polarissports Heritage:
Polaris has a long history in powersports, starting with snowmobiles and expanding into ATVs, becoming a significant player in the off-road vehicle market.
Explorer Series:
The Explorer series was Polaris's entry into larger displacement utility ATVs, offering a blend of performance and work capability.
Production Period:
The Explorer 500 was part of Polaris's ATV lineup in the mid-to-late 1990s, a period of significant growth and innovation in the ATV industry.
