This manual covers the Polaris Sportsman Xplorer 500, produced between 1996 and 2003. These ATVs are recognized for their reliable design, straightforward construction, and ease of maintenance, making them ideal for home repairs. With diligent care and regular servicing, your ATV is engineered to provide many years of dependable performance. This guide is designed to assist owners and technicians in understanding and maintaining these capable machines.
This comprehensive service manual provides detailed information essential for the upkeep and repair of your Polaris Sportsman Xplorer 500. It covers a wide range of topics, including general information, troubleshooting, lubrication, engine maintenance, fuel and cooling systems, drivetrain components, electrical systems, suspension, steering, brakes, and bodywork. With its extensive contents and clear explanations, this manual serves as an invaluable resource for performing routine maintenance, diagnosing issues, and completing repairs, ultimately helping to prolong the life and ensure the optimal performance of your ATV.
1996 - 2003 Polaris Sportsman Xplorer 500 Service Manual.
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 may already have a user manual that youve been using for routine maintenance, you need only assure that you have on hand a service manual for any more in-depth repairs that maybe 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.
Contents include the following topics:
General Information
Troubleshooting
Lubrication, maintenance and tune-up
Engine top end
Engine Lower end
Fuel system
Cooling system
Clutch/drive belt system
Transmission
Front drive system
Electrical system
Front suspension and steering
Rear suspension
Brakes
Body
2001-2003 Service supplement
Wiring diagrams
1996 - 2003 Polaris Sportsman Xplorer 500 Service Manual.
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 may already have a user manual that youve been using for routine maintenance, you need only assure that you have on hand a service manual for any more in-depth repairs that maybe 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.
Contents include the following topics:
General Information
Troubleshooting
Lubrication, maintenance and tune-up
Engine top end
Engine Lower end
Fuel system
Cooling system
Clutch/drive belt system
Transmission
Front drive system
Electrical system
Front suspension and steering
Rear suspension
Brakes
Body
2001-2003 Service supplement
Wiring diagrams
