Product Category:
Powersports Service Manual
Target User:
Owners and technicians servicing the 1997 Polaris ATV Explorer 500.
Value Proposition:
Provides dealer-level repair and maintenance information for DIY or professional use.
Competitors:
Other independent repair manuals (e.g., Haynes, Clymer) or dealer-specific documentation.
Advantage:
Authentic factory data ensures accuracy and completeness, crucial for complex repairs and diagnostics.
Content Scope:
Covers all major mechanical, electrical, and body systems for the specified model year.
Usability:
Downloadable PDF format offers convenience and portability for workshop use.
Engine Internal:
Engine Top End (cylinder head, valves, piston, rings), Engine Lower End (crankcase, crankshaft, connecting rod, bearings)
Fuel System:
Carburetor tuning and overhaul, fuel pump, fuel lines, fuel tank inspection
Cooling System:
Radiator, coolant, fan, hoses, thermostat (if applicable to this model)
Drivetrain Clutch:
Clutch/Drive Belt System (clutch assembly, drive belt inspection, adjustment, replacement)
Transmission:
Transmission overhaul, gear inspection, shifting mechanism
Front Drive:
Front Drive System (component inspection, maintenance, potential repairs)
Electrical System:
Ignition system, starting system, charging system (alternator/stator), lighting, battery, fuses, wiring harness
Suspension Front:
Front Suspension and Steering (shocks, A-arms, ball joints, tie rods, steering column, wheel bearings)
Suspension Rear:
Rear Suspension (shock absorber, swingarm, bearing, U-joints if applicable)
Brakes:
Brake system inspection, adjustment, hydraulic system (master cylinder, calipers, lines), pad replacement, rotor inspection
Bodywork:
Body panels, fenders, seat, racks, controls, trim removal and installation
Diagnostics:
Troubleshooting guides for common and uncommon issues, diagnostic procedures
Wiring Diagrams:
Comprehensive electrical wiring schematics for fault finding and repair
Maintenance:
Lubrication, tune-up procedures, fluid changes, filter replacement, belt inspection/replacement
Repair:
Step-by-step instructions for component removal, overhaul, and reinstallation across all covered systems
Troubleshooting:
Systematic approach to diagnosing and resolving mechanical and electrical problems
Disassembly Assembly:
Detailed instructions for taking apart and putting back together major components and systems
Depth Level:
Comprehensive Factory Level
Detail Level:
Detailed illustrations, diagrams, and step-by-step instructions
Target Audience:
Professional technicians and advanced DIY mechanics
Engine Type:
Four-stroke, Single-cylinder (common for this era's 500cc Polaris models)
Displacement:
Approximately 499cc (specifics would be detailed in the manual)
Bore X Stroke:
Detailed specifications available in the manual.
Compression Ratio:
Detailed specifications available in the manual.
Horsepower:
Typically in the range of 25-30 HP for this engine configuration, specific figures in manual.
Torque:
Specific torque figures would be detailed in the manual.
Carburetor Type:
Likely a single Mikuni or Keihin carburetor, specific model number in manual.
Fuel Type:
Unleaded gasoline, specific octane rating in manual.
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
Specific engine oil viscosity (e.g., SAE 10W-40 or 20W-50) and API service classification detailed in manual.
Oil Capacity:
Approximate oil capacity would be listed, typically around 2.5-3 quarts.
Wheelbase:
Approximate wheelbase for this model is around 50-52 inches. Exact figure in manual.
Length:
Approximate length around 75-80 inches. Exact figure in manual.
Width:
Approximate width around 45-48 inches. Exact figure in manual.
Height:
Approximate height around 45-48 inches. Exact figure in manual.
Dry Weight:
Likely in the 550-650 lbs range. Exact figure in manual.
Payload Capacity:
Specifications for rack load capacity would be in the manual.
Front Tire Size:
Commonly 23x8-12 or similar. Exact size in manual.
Rear Tire Size:
Commonly 23x10-12 or similar. Exact size in manual.
Oil Change:
Typically every 100-200 hours or annually. Specific interval detailed in manual.
Air Filter Cleaning:
Recommended at regular intervals, especially in dusty conditions. Specific schedule in manual.
Spark Plug Replacement:
Recommended every 6-12 months or as per manual's mileage/hour recommendations.
Drive Belt Inspection:
Crucial for CVT longevity, inspect every 50-100 hours. Detailed inspection and replacement guide in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid, as specified in manual.
Coolant Type:
Ethylene glycol based antifreeze (e.g., permanent type), mixed 50/50 with distilled water. Exact type and capacity in manual.
Cv Boot Wear:
Common wear item on ATVs; manual provides replacement procedures.
Carburetor Maintenance:
Carburetors can become clogged over time; manual details cleaning and tuning.
Electrical Connector Corrosion:
A potential issue in wet environments; manual's electrical section is vital for diagnosis.
Manufacturer:
Polaris Industries, a well-established manufacturer of ATVs and powersports vehicles.
Explorer Series:
The Explorer 500 was part of Polaris's early utility and recreational ATV lineup, preceding models like the Sportsman.
Key Innovations Of Era:
This era saw Polaris adopting more robust chassis designs, independent rear suspension on some models, and reliable powertrains.
Production Period:
Mid-to-late 1990s, representing a significant period of growth for the ATV market.
