Polaris SPORTSMAN 500 DUSE Manuals

Manuals and User Guides for Polaris SPORTSMAN 500 DUSE. We have 1 Polaris SPORTSMAN 500 DUSE manual available for free PDF download: Service Manual

Polaris SPORTSMAN 500 DUSE Service Manual

Polaris SPORTSMAN 500 DUSE Service Manual (381 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 39.97 MB

Table of Contents

Chapter Index

1
- Table of Contents
  1
- General Information
  3
  - Identification Numbers
    3
- Model Identification
  3
  - Engine Serial Number Location
    3
- Replacement Keys
  4
- Model Color Identification
  5
- Machine Dimensions
  10
  - Spring Position (Sheave)
    15
- Paint Codes
  19
- Publication Numbers
  19
- Standard Torque Specifications
  20
  - Decimal Equivalents
    23
- Decimal Equivalent Chart
  25
  - Sae Tap Drill Sizes
    25
- Glossary of Terms
  26
Chapter 2 Maintenance

28
- Chapter 1
  28
- Periodic Maintenance Chart
  29
- Pre-Ride Inspection
  30
- Front Gearcase Lubrication
  37
- Transmission Lubrication
  38
- Shift Linkage Adjustment
  39
  - Transmission Gearshift Adjustment
    39
  - Throttle Operation
    41
- Idle Speed
  42
- Pilot Screw Adjustment
  42
- Fuel Filter
  44
- Fuel System
  44
- Carburetor Draining
  45
- Compression Test
  46
- Engine Mounts
  46
- Battery Maintenance
  47
- Ignition Timing
  48
- Spark Plug
  48
- Cooling System Hoses
  49
- Coolant Level Inspection
  50
- Radiator Coolant Level Inspection
  50
- Air Box Sediment Tube Service
  52
- Breather Filter Inspection
  52
- Breather Hose
  52
- Recoil Housing
  53
- Engine Oil Level
  54
- Oil Change/Filter
  54
- Valve Clearance
  56
  - Exhaust Valve Clearance Adjustment
    57
  - Intake Valve Clearance Adjustment
    57
  - Exhaust Pipe
    62
  - Brake Pad Inspection
    63
  - Auxiliary Brake Testing
    64
  - Front Suspension
    65
- Rear Suspension
  65
- Controls
  66
- Wheel Removal/Installation
  67
- Tire Inspection
  68
- Tire Pressure
  68
Chapter 3 Engine

69
- Torque Specifications
  70
- Torque Patterns
  71
- Piston Identification
  72
- Engine Service Data
  73
- Cooling System
  75
- Cooling System Specifications
  76
- Accessible Components
  77
- Engine Removal
  78
- Engine Installation Notes
  79
- Cleaning the Cylinder after Honing
  80
- Honing to Oversize
  80
- Crankshaft Straightening
  81
- EH42PL / EH50PL Engine Lubrication
  84
- EH42PL / EH50PL Engine Exploded View
  85
- Cam Chain Tensioner Inspection
  87
- Rocker Arm/Shaft Inspection
  88
- Cylinder Head Inspection
  95
- Cylinder Head Warpage
  95
- Cylinder Head Disassembly
  96
- Valve Inspection
  98
- Combustion Chamber
  99
- Valve Seat Reconditioning
  100
- Cylinder Head Assembly
  104
- Valve Sealing Test
  105
- Piston Removal
  108
- Cylinder Inspection
  109
- Piston/Rod Inspection
  111
- Piston Ring Installed Gap
  112
- Crankcase Disassembly
  113
- Starter Drive Removal/Inspection
  113
- One Way Valve
  116
- Crankcase Separation
  117
- Oil Pump Removal/Inspection
  118
- Oil Pump Assembly
  120
- Counter Balancer Shaft Removal/Inspection
  121
- Crankshaft Removal/Inspection
  122
- Crankcase Bearing Inspection
  123
- Crankcase Inspection
  124
- Crankshaft End Play Adjustment
  125
- Counter Balancer Shaft End Play Adjustment
  127
- Pump Shaft Oil Seal Installation
  128
- Crankcase Assembly
  129
- Water Pump Mechanical Seal Installation
  130
- One Way Valve Installation
  132
- Piston Ring Installation
  133
- Piston Installation
  134
- Cylinder and Head Installation
  135
- Cylinder Installation
  135
- Cylinder Head Installation
  136
  - Camshaft Installation and Timing
    137
  - Camshaft Timing
    137
  - Cam Chain Tensioner Installation
    140
- Oil Pipes
  142
- Thermostat Installation
  142
- Recoil Disassembly/Inspection
  143
- Recoil Assembly
  145
Chapter 4 Fuel System/Carburetion

150
- Jetting Guidelines
  151
- Main Jet Selection
  151
- Fuel Flow Diagram
  153
- Mikuni Jet Part Numbers
  154
- CV Carburetor System Function (4 Cycle)
  155
  - Mikuni CV Carb Operation
    156
  - Float System
    158
  - Main System
    158
  - Carburetor Cleaning
    162
  - Carburetor Inspection
    163
  - Carburetor Assembly
    164
  - Float Height Adjustment
    165
  - Fuel Level
    166
  - Needle and Seat Leakage Test
    166
- Fuel Pump Exploded View
  168
- Troubleshooting
  169
Chapter 5 Body and Steering

171
- Body Assembly Exploded View
  173
- Cover/Panel Removal
  174
- Headlight Pod Exploded View
  175
- Side Panel Removal
  176
- Steering Assembly, Exploded View
  177
- A-Arm Replacement
  178
- Rear Suspension Assembly
  179
- Strut Assembly
  180
  - Front Strut Cartridge Replacement
    181
  - Ball Joint Replacement
    182
- Decal Replacement
  183
Chapter 6 Pvt System

184
- Steering Post Assembly
  183
- Chapter 5
  184
- Drive Clutch Operation
  186
- Driven Clutch Operation
  186
- PVT System Operation
  186
- Pvt Drying
  187
- PVT Maintenance/Inspection
  187
- Pvt Overheating
  188
- PVT Disassembly
  189
- PVT Assembly
  191
- PVT Sealing and Ducting Components
  192
- Drive Clutch Spring Specifications
  194
- Shift Weights
  195
  - Button to Tower Clearance Inspection
    196
  - Shift Weight Inspection
    196
- Drive Clutch Exploded View
  197
- Drive Clutch Inspection
  197
- Drive Clutch Disassembly
  198
- Spider Removal
  199
- Drive Clutch Assembly
  201
- Drive Belt Tension
  202
- Drive Belt Removal/Inspection
  203
- Drive Belt Installation
  204
- Clutch Alignment /Offset
  205
- Drive Clutch Bushing Service
  206
- Driven Clutch Disassembly/Inspection
  210
- Driven Clutch Assembly
  213
- EBS Theory of Operation
  218
- EBS Exploded View
  220
- Drive Clutch Inspection
  221
- Moveable Sheave Bushing Inspection
  222
- Troubleshooting
  230
Chapter 7 Final Drive 7

232
- Final Drive
  233
  - Awd Operation Overview
    234
    
    Awd Front Hub Bearing Adjustment
    237
    
    Awd Front Hub Exploded View
    238
    
    Awd Hub Seal Replacement
    239
  - Hilliard Clutch Disassembly/Inspection
    241
  - AWD Armature Plate Inspection
    242
    
    Awd Front Drive Axle Removal
    243
    
    Awd Front Drive Axle Installation
    244
    
    Awd Front Drive Axle Exploded View
    247
    
    Awd Front Prop Shaft Removal
    250
  - U-Joint Disassembly
    251
  - U-Joint Assembly
    252
    
    Awd Front Housing Removal
    254
    
    Awd Front Housing Assembly
    256
    
    Awd Front Housing Exploded View
    258
  - Rear Hub/Bearing Carrier Removal
    259
  - Rear Hub Installation
    261
  - Rear Hub Disassembly
    262
  - Rear Hub Assembly
    263
  - Rear Drive Shaft Removal
    264
  - Rear Drive Shaft Installation
    265
  - Rear Drive Shaft Service
    266
Chapter 8 Transmission Service

269
- Torque Specifications
  270
- Gear Shift Selector Disassembly
  271
- Gear Shift Selector Removal
  271
- Gear Shift Selector Assembly
  273
- Boot Replacement
  274
- Gear Shift Selector Installation
  274
- Transmission Removal
  275
- Transmission Installation
  278
- Transmission Disassembly
  280
- Transmission Exploded View
  301
- Troubleshooting Checklist
  302
Chapter 9 Brakes

303
- Troubleshooting
  303
- Specifications
  304
  - Brake System Service Notes
    305
  - Brake Pad Kits
    305
  - Brake Noise Troubleshooting
    306
  - Hydraulic Brake System Operation
    307
  - Dual Hydraulic Caliper Bleeding
    308
  - Fluid Replacement/Bleeding Procedure
    310
  - Master Cylinder Disassembly
    312
  - Master Cylinder Inspection
    314
  - Master Cylinder Assembly
    314
  - Master Cylinder Installation
    316
  - Front Pad Removal
    317
  - Front Pad Assembly
    318
  - Front Disc Inspection
    319
  - Front Caliper Removal
    321
  - Front Caliper Disassembly
    321
  - Front Caliper Inspection
    322
  - Front Caliper Assembly
    323
  - Front Caliper Installation
    324
  - Rear Caliper Assembly
    329
  - Troubleshooting
    333
Chapter 10 Electrical

334
- Chapter 9
  334
- Special Tools
  335
  - Electrical Service Notes
    335
  - High Beam Headlight Adjustment
    336
  - Indicator Lamp Replacement
    337
- Timing Check Procedure
  338
- Typical Ignition Timing Curve
  339
- Flywheel Identification
  340
  - Ignition System
    342
- Ignition System Troubleshooting
  344
- Battery Service
  345
  - Battery Installation
    346
  - Load Test
    347
  - Specific Gravity Test
    347
    
    Off Season Storage
    348
    
    Charging Procedure
    348
- Charging System Testing
  349
- Starter System Troubleshooting
  352
  - Voltage Drop Test
    352
  - Starter System
    353
  - Starter Motor Disassembly
    354
  - Armature Testing
    357
  - Starter Assembly
    358
- Starter Drive
  359
- Electronic Speedometer Troubleshooting
  360
- Fan Control Circuit Operation
  368
  - Brake Light Switch
    369
  - Etc Operation Test
    371
- Electrical Notes
  372

Advertisement

Advertisement

Related Products

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Utility Vehicle Automobile Accessories Snowmobiles

More Polaris Manuals