DOWNLOAD PDF Polaris 1996-2003 Sportsman 400500 & Xplorer 500 4x4 Service Repair Manual

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CONTENTS

QUICK REFERENCE DATA . . . . . . . . • . . . • . • . . . . . . . . . . . . . . • . IX CHAPTER ONE . GENERAL INFORMATION Manual organization Notes, cautions and warnings Safety first Cleaning parts Handling gasoline safely Service hints Torqu e sped fica tion s Fas teners Lubrica nts

Threadlocking compound RTV gasket sealant

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Expendable supplies Serial numbers Warning and information labels Basic hand tools Precision measuring tools Spec ial tools Fabricat ing tools Mechanic's tips Beari ng rep lacement

Seals Storage

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CHAPTER TWO . . . . . TROUBLESHOOTING Operatin g requirement s

Fue l sys tem

Troubleshooting instruments Starting the engine

Engine overheating Engine

Start ing diffi culties

Eng ine no ises Cy linder leak dow n test Power tra in Stee ring

Engine is difficult to start Engine starting system Charging system Ignition system Electroni c throttle control

Frame noise Brakes

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