This workshop service manual for the Polaris Sportsman 500 covers repair and overhaul procedures for the 2004, 2005, and 2006 models. It is designed for use by mechanical technicians familiar with general automobile practices and is useful for both professional mechanics and DIY enthusiasts.
The manual includes instructions on components manufactured for the Polaris Sportsman 500, as well as repair procedures for proprietary components. It provides reliable information and emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE.
It offers diagnostic and repair procedures, routine maintenance and servicing information, as well as instructions for more extensive repairs involving engine and transmission disassembly. The manual also includes specifications and procedures available in an authorized Polaris Sportsman 500 dealer service department.
For those intending to do maintenance and repair on their Polaris Sportsman 500, it is essential to use safety equipment and observe safety precautions. The manual also refers to special tools that are recommended or required to accomplish adjustments or repairs, often identified by their Polaris Sportsman 500 special tool number and illustrated.
The content of the service manual depicts parts and/or procedures applicable to the particular product at the time of writing. It contains information such as tune-ups, maintenance, removal & install procedures, assemblies & disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, and more.
Additionally, the manual provides general maintenance information including air cleaner element renewal, battery terminal check, brake hydraulic fluid renewal, choke adjustment check, engine coolant renewal, engine oil and filter renewal, exhaust system check, fluid level checks, spark plug check and renewal, timing belt renewal, tyre checks, and more.
