Market Segment:
Utility All-Terrain Vehicle (ATV)
Target Audience:
Owners, mechanics, and service technicians of Polaris Sportsman 500 ATVs from 1996-2003.
Key Competitors:
Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou, Suzuki King Quad of similar displacement and era.
Vehicle Purpose:
Designed for utility, recreation, trail riding, hunting, and farming tasks.
Manual Value Proposition:
Provides comprehensive, detailed information to enable users to maintain, diagnose, and repair their Sportsman 500, reducing reliance on external repair shops.
Vehicle Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Regions Covered:
North America and global markets where the Sportsman 500 was officially sold
Estimated Page Count:
Hundreds of pages (specific count not provided, but indicative of comprehensive content)
Manual Type:
Service and Repair Manual
Format:
PDF (Downloadable)
Engine Systems:
Engine overhaul, carburetor tuning, ignition system, cooling system, lubrication, exhaust system, internal engine components (pistons, valves, crankshaft, camshaft), cylinder head, cylinder block.
Drivetrain Systems:
Transmission (gearbox), drive shafts, differentials, clutch, final drive, AWD system (if applicable to specific trims).
Chassis And Suspension:
Front and rear suspension (shocks, springs, control arms), steering system, frame, subframe, wheel bearings, bushings.
Braking Systems:
Hydraulic braking system, brake calipers, brake discs (rotors), brake pads, master cylinder, brake lines, parking brake.
Electrical Systems:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, brake lights), electrical components, switches, fuses, relays.
Fuel System:
Fuel tank, fuel lines, fuel pump, carburetor (specific models), fuel filters.
Cooling System:
Radiator, fan, coolant hoses, thermostat, water pump.
Body And Trim:
Body panels, fenders, racks, seat, controls, plastics, decals.
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment (if applicable), lubrication points.
Troubleshooting:
Diagnostic procedures for common problems, fault finding charts, symptom-based troubleshooting.
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly of all major systems.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, dimensional data.
Wiring Diagrams:
Comprehensive electrical system wiring schematics for easy diagnosis and repair.
Assembly Disassembly:
Detailed instructions for taking apart and putting back together various components and the entire ATV.
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
Print Quality:
High-resolution digital scans, allowing for clear printing of all text and diagrams.
Binding Type:
Not applicable (downloadable PDF format)
Paper Type:
Not applicable (digital format)
Searchable Text:
Likely contains searchable text for efficient information retrieval, common in professionally produced PDFs.
Content Type:
Official factory service manual content, often supplemented with common repair procedures.
Engine Type:
4-stroke, SOHC (Single Overhead Camshaft), 2-valve
Displacement:
499cc (approximately 30.4 cubic inches)
Bore X Stroke:
92 mm x 75 mm (typical for this engine family)
Cooling System:
Liquid-cooled
Ignition System:
Electronic Ignition (CDI)
Horsepower:
Approximately 28-30 hp (variations may exist by year/tune)
Torque:
Approximately 27-29 lb-ft (variations may exist by year/tune)
Carburetor Type:
Mikuni BSR 34mm (common across many models in this range)
Fuel Type:
Unleaded gasoline (87 octane or higher recommended)
Recommended Oil Viscosity:
SAE 10W-40 or 20W-50 (depending on ambient temperature, refer to manual for specifics)
Oil Capacity:
Approximately 1.7 L (1.8 US qt) with filter change (verify with manual)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with High/Low range and Reverse.
Drive System:
Shaft Drive, AWD (All-Wheel Drive) engagement system (On-Demand AWD).
Clutch Type:
Sheave-type variable ratio drive and driven clutches.
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (verify with manual for specific viscosity/grade).
Transmission Fluid Capacity:
Approximately 0.7 L (0.75 US qt) (verify with manual).
Length:
Approximately 81 inches (205.7 cm)
Width:
Approximately 46 inches (116.8 cm)
Height:
Approximately 45 inches (114.3 cm)
Dry Weight:
Approximately 590 lbs (268 kg)
Ground Clearance:
Approximately 11.5 inches (29.2 cm)
Front Rack Capacity:
Approximately 50 lbs (22.7 kg)
Rear Rack Capacity:
Approximately 100 lbs (45.4 kg)
Towing Capacity:
Approximately 1,500 lbs (680 kg) (verify with manual)
Wheelbase:
Approximately 50.5 inches (128.3 cm)
Front Tire Size:
25x8-12 (common size, verify with specific model year)
Rear Tire Size:
25x11-12 (common size, verify with specific model year)
Atv Safety Standards:
Adherence to ANSI standards for ATVs is expected for vehicles of this era.
Braking System:
Hydraulic disc brakes on all wheels for consistent stopping power.
AWD System:
On-Demand All-Wheel Drive provides enhanced traction and control in difficult terrain.
Operator Safety:
Handlebar controls, throttle limiter (governors), protective bodywork, and footwells designed to keep the rider secure.
Protective Gear:
Full-face helmet, eye protection, gloves, long pants, and sturdy boots are essential for safe operation.
Engine Oil Change:
Every 100 hours or annually (refer to manual for precise intervals and operating conditions).
Air Filter Maintenance:
Inspect every 25 hours, clean/replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement:
Typically every 100 hours or annually (check gap and condition at each oil change).
Drive Belt Inspection:
Inspect for wear and damage at 50-hour intervals or annually. Replacement usually recommended between 1500-3000 miles or as indicated by wear.
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water is standard, refer to manual for Polaris specific recommendation).
Brake Fluid Type:
DOT 4 brake fluid (verify with manual).
Common Wear Items:
Drive belts, bushings (suspension and steering), wheel bearings, tie rod ends, starter solenoid.
Carburetor Issues:
Clogged jets, diaphragm wear, idle adjustment issues can occur with age and fuel quality.
Electrical Issues:
Corrosion on connectors, faulty regulator/rectifier, starter solenoid failure.
Recommended Parts Sources
Parts Reference:
The manual often includes part numbers for key components, though specific numbers are not listed in the product description. Users may need to consult online parts diagrams or dealerships.
Polaris History:
Polaris Industries Inc. has a long history of manufacturing powersports vehicles, including snowmobiles and ATVs, known for innovation and durability.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, emphasizing comfort, utility, and capability. The 500 model has been a popular and enduring choice.
Production Period:
1996-2003 represents a significant generation of the Sportsman 500, evolving through various refinements.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
