Polaris 500 Worker 4x4 1999-2002 ATV Repair Manual Clymer

Models Covered:

2001-2005 POLARIS Sportsman 400

2006-2007 POLARIS Sportsman 450

2006 POLARIS Sportsman 450 Browning Edition

1996-2010 POLARIS Sportsman 500

2001-2002 POLARIS Sportsman 500 DUSE

2001-2006, 2008-2010 POLARIS Sportsman 500 HO

2000-2002 POLARIS Sportsman 500 RSE

2008-2010 POLARIS Sportsman 500 Touring

2006-2008 POLARIS Sportsman 500 X2

1997-2001 POLARIS Worker 500

1997 POLARIS Xplorer 500

715 pages with color wiring diagrams.

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers /Model identification (2004 models) / Fasteners / Shop supplies / Tools /Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil / Oil pump priming / Oil pressure test / Transmission / Front gearcase oil / Front hub (1996-early 2004 models) / Clutch / Air filter / Fuel tank vent hose / Fuel hose and filter / Brake system / Control cables / Cooling system / Exhaust system / Suspension / Tires and wheels / Lubrication service / Fastener inspection / Valve clearance / Compression test / Spark plug / Ignition timing / Idle speed / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine service / Engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications

CHAPTER FIVE / ENGINE LOWER END
Flywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications

CHAPTER SIX / CARBURETOR AND FUEL SYSTEM
Carburetor operation / Carburetor / Carburetor tests and adjustments / Throttle cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump / Specifications

CHAPTER SEVEN / FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and fuel injector / Fuel pump / Fuel sender / Pressure regulator / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position sensor (TPS) / Engine coolant temperature (ECT) sensor / Electronic control module (ECM) / Self diagnosis / Throttle cable replacement / Air filter air box / Specifications

CHAPTER EIGHT / COOLING SYSTEM
Air cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications

CHAPTER NINE / CLUTCH AND DRIVE BELT
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications

CHAPTER TEN / TRANSMISSION (1996-early 2004 models)
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase oil seal inspection and replacement / Shift selector linkage / Specifications

CHAPTER ELEVEN / TRANSMISSION (LATE 2004-on MODELS)
Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications

CHAPTER TWELVE / FRONT DRIVE SYSTEM
Front hub and Hilliard clutch / (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front drive axle, boots and constant velocity (CV) / joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent / control (2007-on Sportsman 500, X2 and Touring models) / Specifications

CHAPTER THIRTEEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / Alternator stator / Voltage regulator/rectifier / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (fuel injected models) / Ignition coil / Electric starting system / Starter drive gears / Starter solenoid / Headlight system / Taillight and work light / Indicator lamp (1996-2002 models) / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit (late 2004-on models) / Differential solenoid (X2 and Touring models) / Switches / Electronic throttle control (ETC) switch / All wheel drive (AWD) coil / Active descent control (ADC) coil / (2007-on X2 and Touring models) / Cooling system switch and sensor / Fuses and circuit breaker (2008 models) / Speedometer / On-board diagnostics / Winch (models so equipped) / Winch contactor (models so equipped) / Specifications

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Front wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / Specifications

CHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / Lower control arm (X2 and Touring models) / Upper and lower control arm inspection / Stabilizer linkage (all models except X2 and / Touring) / Stabilizer support (all models except X2 and / Touring) / Stabilizer support and bar (X2 and Touring models) / Specifications

CHAPTER SIXTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper / Output shaft brake pad replacement / (1996-1997 models) / Output shaft brake caliper (1996-1997 models) / Output shaft brake pad replacement / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / Rear brake pad replacement (2003-on models / except X2 and Touring) / Rear caliper (2003-on models except X2 and / Touring) / Rear brake pad replacement (X2 and / Touring models) / Rear caliper (X2 and Touring models) / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake bleeding tips / Brake bleeding / Brake fluid draining / Rear brake pedal / Brake disc / Specifications

CHAPTER SEVENTEEN / BODY AND FRAME
Plastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Radiator guard (1996-2003 models) / Radiator brush guard (2004-on models) / Brush guard grill and radiator side shield / (2004-on models) / Rear rack, rail and bumper (1996-2002 models) / Rear rack and rail (2003-on except X2 and / Touring) / Rear rack and handle (Touring models) / Rear fender / Rear quarter panel (X2 models) / Footwell / Footwell support bracket (X2 and Touring models) / Rear storage box (all models except X2 and Touring) / Cargo box (X2 models) / Specifications

INDEX

COLOR WIRING DIAGRAMS

Models covered
Sportsman 400 2001 2002 2003 2004 2005
Sportsman 450 2006-2007
Sportsman 450 Browning Edition 2006
Sportsman 500 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Sportsman 500 RSE 2000 2001 2002
Sportsman 500 DUSE 2001 2002
Sportsman 500 HO 2001 2002 2003 2004 2005 2006, 2008 2009 2010
Sportsman 500 X2 2006 2007 2008 2009 2010
Sportsman Touring 500 2008 2009 2010
Worker 500 1997 1998 1999 2000 2001
Xplorer 500 1997