96-03 Polaris Sportsman Xplorer 500 Service Manual
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Because of their reliable design, relatively simple construction, and ease of repair; ATVs are the ideal machine for maintenance and repair at home. With proper care and routine maintenance, your ATV will provide many years of reliable use. When repairing an ATV, most home mechanics will find them easy to work with and repairs quick and trouble-free.
Scheduled ATV maintenance should occur frequently at regular intervals. This routine maintenance should include changing the oil, inspecting the shift linkage - steering - suspension - coolant system - fuel system - drive belts - engine mounts, changing the spark plugs, and replacing the fuel and air filters. Having a quality service manual specific to your ATV will help you identify the parts of your ATV and assist you during routine maintenance and repair.
Doing routine maintenance on your ATV at home provides many benefits. It is less expensive than having an ATV shop do the maintenance. It prolongs the life of your ATV. And, it provides you a better understanding of the working components of your ATV.
Even with diligent routine maintenance, ATVs may require periodic repairs. In the event that you need to repair your ATV, it will likely be easier if you have been doing your own routine maintenance as you will be more familiar with the mechanics of your engine. Another asset that makes ATV engine repair easier, is access to service manuals and parts catalogues. Since you already have a maintenance manual that youve been using for routine maintenance, you need only assure that you have on hand a parts catalogue for any repairs that are necessary.
Your ATV will provide you with many years of service. Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.
504 pages in english pdf format that enables you to print only what you need.
LUBRICATION, MAINTENANCE AND TUNE-UP
ENGINE TOP END
ENGINE BOTTOM END
CLUTCH DRIVE/BELT SYSTEM
FRONT DRIVE SYSTEM
FRONT SUSPENSION AND STEERING
A small sample of some of the topics covered in this manual: air cleaner, air cleaner housing, air cleaner drain hose, battery, brake fluid, brake fluid replacement, brake pad, brake pads, carburetor assembly, carburetor disassembly, carburetor choke, cylinder compression, cylinder head, cylinder head and pistons, differential, engine idle speed, engine removal, engine oil, engine oil change, engine oil filter, exhaust system, exhaust systems, final drive, flywheel, starter, clutch, frame cover, front brake shoes (pads), front crankcase cover, front drive shaft, fenders, front fenders, mud guards, front mud guard, shock absorber, front wheel, front wheel cylinder, fuel hose, fuel tank, fuel tank cover, gear position switch, gearshift linkage, handlebar switch, headlight, headlight grill, ignition coil, ignition switch, ignition system, inner fender, maintenance chart, maintenance schedule, oil cooler, oil pump, outer fender, rear axle, rear brake pedal, rear fender, recoil starter, reverse shift switch, valve, valves, piston, pistons, electric shift program, electric starter, valve clearance, valve guides, valve seat, seats, wheel hub and knuckle, wheels rims and tires, wiring diagrams and much more.
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