1996-2003 Polaris ATV Sportsman 400 500 Service Manual

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CHAP TER FOURTEEN . BRAKES Disc brakes Front brake pad replacement
Fro nt cal iper Ou tput sha ft brake pad replacement (1996-1997 mode ls) O utput sha ll brake cal iper ( ]996- 1997 mode ls) Outpu t sha ll brake pad repl acement ( I998- on models) Output shaft brake caliper (I 998 -on mode ls)

.. . .. . . 382
Front master cylinder Rear master cylinder
Brak e hose replace ment

Rear brake peda l Rem brake lever ( 1996 -1997 Sweden mod els) Foot brak e (199 8-on Sw eden model s) Brake d isc Bleeding the sys te m

CHAPTER FIFTEEN BODY
Seat
Radiator guard
Rear rack

. . . .. .. .. . 425

Front rack and grille
Side panels Front fender Fro nt bum per (models so eq uipped )

Rear fender
Footv..'ells Rear bump er (mode ls so eq uipped)

SUPPLEMENT . 2001-2003 SERVICE INFORMATION
Starting the engine

. . . . . . . . . . . 437
Transmission Lighting system Electrical components
Stee ring sha ll (2002-on mode ls) Rear hub and bearing carrier (200 3 mode ls) Rear brake pad replacement (2003 models) Rear ca lipers (200 3 mod els)

Ignition system
Periodic maintenance Engine tUIl C- Up Cy linde r block

Piston and piston rings Engine
Flywhee l and stator plate Carburetor (Sportsman 500 H.G. models)

Front master cylinder
Rear master cylinder (2003 models) Rea r brake disc (200 3 mode ls) Brak e hose replace men t (2003 models)

Cleaning and inspection Carburetor tests and adjustments
Drive belt Driv en pulley (200 3 mod els bui lt afte r 07/08102)

INDEX

.

.470 .476

WIRING DIAGRAMS .

QUICK REFERENCE DATA
ATV INFORMATION
MODEL: VIN NUMBER:, ENGINE SERIAL NUMBER : CARBURETOR SERIAL NUMBER OR 1 MARK: .0. YEAR: _ _ _ _

TIRE INFLATION PRESSURE (COLD)'
Model Front wheels Rear wheels kPa 34.5 34.5

PSI
5 5

"Tlre pressure for original equipment tires. Aftermarket tires may require different Inflation pressure.

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES Item
Engine 011 Transmission all Lubricant or fluid type Polaris Premium 4 Synthetic 10W/4Q or 10W/40 motor all Polaris synthetic gear case 011 (part No. 2871478) Polaris front gearcase lube (part No. 2871653), or API GL5 80·90 gear lube Polaris demand drive hub fluid (part No. 2871654), or ATF Type F. DOT 3 brake fluid 50:50 mixture ethylene glycol·based coolant compounded for aluminum radiators and engines Polaris all season grease, or equivalent

Front gear case
Front hubs Brake fluid Coolant

Grease

RECOMMENDED CAPACITIES

Item
Engine all Transmission all Front gear case (all years) Front hubs Coolant

Quantity 1.89 L (2 U.S. qts.) 946.3 cc (32 U.S. oz.} 96 cc (3.25 U.S. oz.) 75 cc (2.5 U.S. oz.) Approx. 2.16 L (2.25 U.S. qts.)

IX

MAINTENANCE AND TUN E·UP T ORQ UE SPECIFICATIONS

Item
Crankcase oil drain plug Cylinder head cover screws Front gear case drain plug
Handlebar up per holder bol ts Oi l tank drain plug

N'm
19 8.2 9.4 13·17 19 20 6-7 21 21

in... lb.
72
83 115-150

ft.· lb.
14

0 11 tank screen and fitting Valve adjuster locknuts
Whee/lug nuts

14 15 53-62

Front Rear

15 15

MAINTENANCE AND TUNE·UP SPEC IF IC AT IO NS

Item
Disc brake pad thickness wear limit
2003 Sportsman 500 & 500 H.O.

Spec ific at ion

Rear brake All other models and years Front and rear brakes Valve clearance (cold)
Intake and ex haust Spark plug

4.6 mm (0.180 In.) 3.8 1 mm (0.150 In. ) 0.15 mm (0.006 In .)

400 cc
Heat range Gap 500 ee Heat range 1996-1997 1998-200 1 2002·on Gap 1996 · 1998 1999-2000 200 1·on Idle sp eed 1996-1988 , 2001-on 1997·2000 Carburetor pilot air screw (34 mm) 1996 1997·1998 1999-2000 2001-on (400 ee) Carburetor pilot air screw (40 mm ) 2001 2002-on

NG K BKR 5E 0.9 mm (0.036 in.)

NGK BKR5ES NGK BKR5E NGK BKR6E 0.6-0.7 mm (0.02 4-0.028 in . 0.7 mm (0.028 In.) 0.9 m m (0.036 in.) 1100-1300 rpm 1000-1400 rpm

1 1/2 turns ou t 2 turns out 2 5/8 turns out 23/4 turns out

2 1/2 turns out 2 turns out
REPLACE MENT BULBS

Item Headlights Grill mounted lights 1996 1997 1998-on Taillight Brake light Indicator lights 1996 1997-on

Spec ificati on
12 volt , 60/60 watt Halogen

12 12 12 12 12

volt , 37.5 watt (2) volt, 35 watt (2) volt, 27 watt volt, 8.26 watt volt , 6 .9 watt

12 volt , 1.25 wa tt 12 volt,l.0 watt

x