2002 Polaris Sportsman 500 Parts 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 parts 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.
65 pages in english pdf format that enables you to print only what you need.
Contents include the following topics with exploded diagrams and part number lists.
REAR CAB and SEAT
REAR RACK MOUNTING
FRONT RACK and BUMPER MOUNTING
CV JOINT BTB
CONTROLS -- THROTTLE ASM./CABLE
CONTROLS - MASTER CYLINDER/BRAKE LINE
HANDLEBAR and HEADLIGHT POD
SWING ARM/SHOCK MOUNTING
GEARCASE/BRAKE and CHAIN COVER MOUNTING
REAR WHEEL DRIVE
PISTON and CRANKSHAFT
CRANKCASE and CYLINDER
PART NUMBER INDEX
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