Polaris Sportsman Xplorer 500 Service Manual | 1996-2003 ATV | PDF Instant Download

Polaris Sportsman Xplorer 500 Service Manual PDF Service Repair Manual

This downloadable PDF service repair manual is for Polaris Sportsman Xplorer 500 Service Manual covering 1996-2003. It is prepared for owners, technicians and DIY repair work, with the service procedures, diagnostics, specifications, diagrams and troubleshooting information needed to maintain and repair the ATV correctly. The source listing states 476 pages of service information.

What's Included

• Complete engine top end disassembly and assembly - camshaft, cylinder head, valves, piston and rings, camshaft chain and sprockets
• Engine lower end service - crankcase, crankshaft, balancer shaft, flywheel, stator, oil pump, and recoil starter
• Carburetor fuel system diagnostics - carburetor operation, cleaning, inspection, tests, adjustments, throttle cable, fuel tank, fuel pump, and air filter
• Electrical, ignition, and charging system procedures - CDI, alternator, voltage regulator, starter, lighting, switches, and wiring diagrams
• Cooling system inspection and maintenance - radiator, cooling fan, coolant pump, thermostat, and temperature sensors
• Clutch and drive belt system service - drive pulley, driven pulley, drive belt, and PVT air cooling system
• Transmission and front drive system overhaul - gearcase, shift shafts, output shaft, front driveshaft, front drive unit, and Hillard clutch
• Front and rear suspension repair - strut cartridge, control arms, shock absorbers, rear hub and bearing carrier, rear axles, and stabilizer linkage
• Steering system service - handlebar, tie rods, steering shaft, and wheel alignment
• Brake system inspection and hydraulic service - disc brakes, front and rear calipers, master cylinders, brake hose replacement, and brake bleeding
• Troubleshooting charts and diagnostic workflows for engine, fuel, charging, ignition, drivetrain, steering, and brake systems
• OEM specifications and torque tables
• High-resolution wiring diagrams and system schematics

Models Covered

• Polaris Sportsman 400 4x4
• Polaris Sportsman 500 4x4
• Polaris Sportsman 500 H.O. 4x4
• Polaris Xplorer 500 4x4

Table Of Contents

• Chapter One: General Information
• Chapter Two: Troubleshooting
• Chapter Three: Lubrication, Maintenance and Tune-Up
• Chapter Four: Engine Top End
• Chapter Five: Engine Lower End
• Chapter Six: Fuel System
• Chapter Seven: Cooling Systems
• Chapter Eight: Clutch/Drive Belt System
• Chapter Nine: Transmission
• Chapter Ten: Front Drive System
• Chapter Eleven: Electrical System
• Chapter Twelve: Front Suspension and Steering
• Chapter Thirteen: Rear Suspension
• Chapter Fourteen: Brakes
• Chapter Fifteen: Body
• Supplement: 2001-2003 Service Information
• Index
• Wiring Diagrams

PDF Features

• OEM-quality PDF (searchable and printable)
• High-resolution diagrams and schematics
• Polaris original service manual
• Adobe Acrobat (PDF) format
• Fully Searchable
• Easily print any or all content
• Provided via direct download shortly after purchase
• Everything needed to repair & maintain your ATV
• Troubleshooting instructions, diagrams and reference material
• Works on PC, Mac, tablet, and mobile devices
• Important: This is a digital PDF manual. No paper book will be provided
• NEED ANOTHER LANGUAGE?
• In many cases we can provide translated versions in German, French, Dutch, Italian or any other language. Just ask!
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• WHAT OUR CUSTOMERS ARE SAYING
• Better than the hard copy I had
• Less than 5 minutes after purchase I had already downloaded my manual. Great service
• This was a life saver for a piece of equipment I bought that did not have the manuals
• The manual was just what I needed to fix the problem with my lower unit
• Great customer service. My manual wasn't showing all the pictures and it turned out to be my PDF viewer. The seller helped me determine the problem and get it fixed
• Exactly what I needed. Zero complaints

Digital Download

This is a digital PDF manual. No printed book, CD or USB drive will be shipped. After purchase, download the file and view it on a computer, tablet or phone, or print only the pages you need for the job.