Electrical Diagram 1998 Polaris 500 Sportsman

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Polaris 1998 Sportsman 500 Manuals

Manuals and User Guides for Polaris 1998 Sportsman 500. We have 2 Polaris 1998 Sportsman 500 manuals available for free PDF download: Service Manual

Polaris 1998 Sportsman 500 Service Manual (634 pages)

Polaris ATV And Light Utility Vehicle Service Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 48.29 MB

Table of Contents

• • 2

    Safety Labels and Instructions

  • 3

    Table of Contents

  • 5

    Table of Contents

• 6

  Chapter 1

  • 6

    Model Identification

    • 6

      Engine Serial Number Locationi

    • 6

      Transmission ID Number Location

    • 6

      Carburetor ID Number Location

    • 7

      1996 Model Identification

    • 8

      Vehicle Identification Number (1997 and Later Model Years)

    • 10

      1996 Publication Numbers

    • 10

      1997 Publication Numbers

    • 11

      1998 Publication Numbers

    • 11

      Service Traning Videos

    • 12

      Service/Information Bulletins

    • 13

      Bulleting Index - 1996 by Model

    • 14

      Bulleting Index - 1997 by Model

    • 14

      Bulleting Index - 1998 by Model

  • 16

    1997 Paint Codes

    • 18

      Specifications 1997

    • 23

      Specifications 1998

  • 26

    Standard Torque Specifications

  • 27

    Decimal Equivalents

  • 28

    Conversion Table

  • 29

    Tap Drill Charts

    • 29

      SAE Tap Drill Sizes

    • 29

      Metric Tap Drill Sizes

  • 30

    Warranty

  • 31

    Service Tips

  • 32

    Glossary of Terms

  • 35

    Special Tools

  • 36

    Routing Diagrams

    • 36

      Magnum Routing Diagram

    • 39

      Hoses Diagram

    • 40

      300 Fan Motor Wiring Diagram

    • 41

      Wire Harness Diagram

    • 42

      Chassis/Suspension Service Tools

    • 42

      Transmission Tool Kit - Shaft Drive

    • 42

      Yoke Gauge Tool - Shaft Drive

    • 43

      Mity Vac Pump Kit

    • 43

      Small Battery Hydrometer

    • 43

      Transmission Seal/Bearing Driver - 50 MM

    • 43

      CV Boot Clamp Pliers

    • 45

      Glossary (2)

    • 48

      Magnum Routing Diagram (Cont.)

    • 51

      Hosed Diagram (2)

    • 52

      300 Fan Motor Wiring Diagram (2)

    • 53

      Wire Harness Diagram (2)

    • 54

      Oil Tank Vent Line Routing (1996 Sportsman 500) Diagram

    • 56

      Maintenance

• 58

  Chapter 2

  • 58

    Periodic Maintenance Chart

    • 59

      Pre-Ride/Daily Inspection

    • 60

      Recommended Lubricants and Capacities

    • 62

      Lubrication Chart

    • 65

      Lubrication Chart - Type IV Transmission (Shaft Drive)

    • 67

      Front Gearcase Lubrication

    • 67

      Gearcase Lubricant Change

    • 68

      Carburetor Adjustments

      • 68

        Idle Speed Adjustment

      • 68

        Throttle Cable/Electronic Throttle Control ETC Switch Adjustment

      • 68

        Throttle Operation

      • 69

        Choke Adjustments

      • 69

        Throttle Cable Adjustment

      • 69

        Throttle Control Lever Stop Adjustment

      • 70

        Air Screw Adjustment - 2-Stroke Models

      • 70

        Pilot Screw (Idle Mixture) Adjustment - 4-Stroke Models

      • 72

        Carburetor Float Bowl Draining

      • 72

        Fuel Filter

      • 72

        Fuel Lines

      • 72

        Vent Lines

    • 73

      Carburetor Draining

      • 74

        Breather Filter Inspection

      • 74

        Breather Hose

      • 74

        Breather System (4 Strokes)

    • 76

      Compression Test

    • 76

      General Maintenance

      • 77

        Battery Maintenance

      • 78

        Engine Mounts

      • 78

        Ignition Timing

      • 78

        Spark Plug Maintenance

      • 79

        Coolant Level Inspection

      • 79

        Coolant Strength

      • 79

        Cooling System Pressure Test

      • 79

        Radiator

      • 80

        Oil Pump Adjustment Procedure

      • 83

        If Oil Starvation Is Suspected

      • 83

        Oil Pump Bleeding Procedure

      • 84

        Counter Balance Oil Changing Procedure

      • 84

        Counter Balancer Lubrication (400)

      • 84

        Procedure for Adding Oil (400)

      • 84

        Recoil Housing

      • 85

        Air Cleaner - Trail Boss, Xpress 300, Xplorer 300, Xplorer 400

      • 85

        Dual Stage Air Cleaner

      • 85

        Primary Pre-Cleaner Foam Boot

      • 86

        Cleaning the Main Filter

      • 86

        Secondary (Main) Filter

      • 86

        Secondary Filter Removal and Installation Procedure

      • 87

        Air Filter Service -Sport, Scrambler 400

      • 88

        Air Filter Service - Trail Blazer

      • 89

        2 Stroke Engine Maintenance

      • 89

        Oil Filter (2 Strokes)

      • 90

        4 Stroke Engine Maintenance

      • 92

        Air Filter - 4 Stroke Engine

      • 92

        Air Filter Main Element

      • 92

        Pre-Filter Service

      • 93

        Air Box Sediment Tube

      • 94

        Air Filter Service - Scrambler 500

      • 94

        Air Filter Service - Sportsman 500, Xplorer 500

      • 96

        Check Engine Oil (4 Stroke)

      • 96

        Oil and Filter Change (4 Stroke)

      • 97

        Engine Sump Drain Plug View

      • 100

        Valve Clearance

      • 101

        Exhaust Valve Clearance Adjustment

      • 101

        Intake Valve Clearance Adjustment

      • 102

        Throttle Cable Lubrication

    • 103

      Toe Alignment Inspection

    • 104

      Camber and Caster Adjustment

    • 104

      Chassis Maintenance

      • 104

        Steering Maintenance

      • 104

        Toe Alignment Inspection (Chassis Maintenance)

      • 105

        Changing Front Hub Fluid

      • 105

        Front Hubs (4X4 AWD Model)

      • 105

        The Rod End Inspection

      • 106

        Exhaust Pipe

      • 107

        Brake Fluid Level Inspection

      • 107

        Brake System Inspection

      • 107

        Wear Line

      • 108

        Auxiliary Brake Adjustment

      • 108

        Auxiliary Brake Testing

      • 108

        Auxiliary Mechanical Brake System

      • 108

        Hose/Fitting Inspection

      • 109

        Drive Chain and Sprocket Inspection

      • 109

        Drive Chain Inspection

      • 109

        Rear Drive Chain Note

      • 110

        Rear Drive Chain Tension Adjustment

      • 111

        Drive Chain Adjustment, Concentric Swingarm

      • 113

        Center/Front Drive Chain Inspection/Adjustment

      • 113

        Center/Front Drive Chain Slack Adjustment

      • 113

        Sprocket Inspection

      • 114

        6X6 Rear Axle Drive Chain Adjustment

    • 114

      Drive Chain Inspection/Adjustment

      • 114

        Final Drive Chain

      • 114

        Rear Axle (6X6 Middle Axle) Adjustment Procedure

      • 115

        Controls Check

      • 115

        Front Suspension

      • 115

        Rear Suspension

      • 116

        Transmission Lubrication

      • 116

        Transmission Oil Change - Dipstick Models

      • 116

        Transmission Oil Changing Procedure

      • 117

        Transmission Lubrication - Type V Shaft/Chain

      • 117

        Transmission Oil Change Procedure

      • 118

        Transmission Linkage Adjustment

      • 118

        Transmission Vent Line Routing

      • 119

        Wheel Installation

      • 119

        Wheel Removal Front or Rear

      • 119

        Wheel, Hub, and Spindle Torque Table

      • 119

        Wheels Inspection

      • 120

        Frame, Nuts, Bolts, Fasteners

      • 120

        Tire Pressure

      • 120

        Tire Tread Depth

      • 122

        Engine

      • 124

        2 Stroke Engine Torque Specifications

      • 124

        4 Stroke Engine Torque Specifications

      • 125

        Engine Fastener Torque Patterns

      • 126

        1996 To Current Engine Specifications

      • 126

        Piston Identification

      • 127

        EC38PL Engines

      • 127

        Jetting Guidelines for Round-Port Pistons

      • 129

        EH42PL/EH50PL Engine Service Data

      • 131

        Cooling System

      • 131

        Radiator Cap Pressure Test

      • 131

        System Pressure Test

      • 132

        Cooling System Specifications

      • 132

        Recommended Coolant

      • 133

        2 Stroke Engine Removal

      • 133

        Engine Removal Preparation, Typical (2 Stroke)

      • 136

        Bleed Cooling System

      • 136

        Engine Break in Period (2 Strokes)

      • 136

        Engine Installation Notes (2 Stroke)

      • 136

        Transmission Readjustment

      • 137

        EC25PF/EC28PF Engines Disassembly

      • 138

        Crankshaft Alignment

      • 139

        EC25PF/EC28PF Engines Assembly

      • 139

        Measure Crankshaft Width - Bearings Installed

      • 140

        Connecting Rod Side Clearance

      • 144

        EC25PF/EC28PF Engines Installation

      • 145

        Oil Pump End Play Adjustment

      • 146

        Oil Check Valve Testing (250/400)

      • 146

        Oil Check Valve Testing (300)

      • 147

        EC25PF Engine - Recoil Disassembly

      • 148

        EC25PF Engine - Recoil Assembly

      • 150

        EC38PL Engine Disassembly

      • 156

        Water Pump Impeller Clearance

      • 158

        Cylinder Hone Selection/Honing Procedure

      • 159

        Cylinder Inspection/Measurement

      • 159

        Piston Inspection/Measurement (Generic)

      • 159

        Piston/Cylinder Clearance (2 Strokes)

      • 160

        Piston Pin/Needle Bearing Inspection

      • 160

        Piston Ring Installed Gap

      • 161

        Connecting Rod Small End Inspection

      • 162

        EH42PL/EH50PL Engine Exploded View

      • 163

        EH42PL/EH50PL Lubrication/Oil Flow

      • 163

        Oil Pressure Test

      • 164

        EH42PL/EH50PL Engine Diagram

      • 164

        EH42PL/EH50PL Oil Flow Chart

    • 165

      Crankcase

    • 165

      Cylinder Head Bolts

      • 165

        EH42PL/EH50PL Engine Removal

      • 166

        AWD Models

      • 166

        PVT Disassembly, All Models

      • 167

        Recoil/Starter Removal

      • 169

        Final Coolant Draining/Engine Removal

      • 170

        Cam Chain Tensioner/Rocker Arm/Camshaft Removal

      • 170

        EH42PL/EH50PL Engine Installation

      • 170

        EH42PL/EH50PL Engine: Bleed Cooling System

      • 170

        Oil Supply

    • 171

      Cam Chain Tensioner

      • 171

        To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke

      • 172

        Rocker Arm/Shaft Inspection

      • 172

        Rocker Arm/Shaft Removal

      • 174

        Camshaft Removal

      • 175

        Automatic Compression Release Installation

      • 175

        Automatic Compression Release Removal/Inspection

      • 176

        Camshaft Inspection

      • 177

        Cylinder Head Removal

      • 178

        Cylinder Head Disassembly/Inspection

      • 179

        Cylinder Head Disassembly

      • 179

        Cylinder Head Warpage

      • 181

        Valve Inspection

      • 182

        Combustion Chamber

      • 182

        Cylinder Head Reconditioning

      • 182

        Valve Guide Removal/Installation

      • 182

        Valve Seat Inspection

      • 183

        Valve Seat Reconditioning

      • 186

        Cylinder Head Assembly

      • 187

        Cylinder/Piston Removal and Inspection

      • 187

        Valve Sealing Test

      • 188

        Piston Removal

      • 189

        Cylinder Inspection

      • 190

        Piston to Cylinder Clearance

      • 192

        Crankcase Disassembly

      • 192

        Piston Ring Installed Gap (EH42PL/EH50PL)

      • 193

        Starter Drive Removal/Inspection

      • 194

        Cam Chain/Tensioner Blade

      • 194

        Flywheel/Stator Removal/Inspection

    • 194

      Stator Plate

      • 195

        Crankcase Separation

      • 195

        One Way Valve

      • 196

        Oil Pump Removal/Inspection

      • 198

        Counter Balancer Shaft Removal/Inspection

      • 198

        Oil Pump Assembly

      • 199

        Crankshaft Removal/Inspection

      • 200

        Crankcase Bearing Inspection

      • 200

        Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal

      • 201

        Crankcase Assembly

      • 201

        Crankshaft

      • 201

        EH42PL/EH50PL Engine Assembly

      • 201

        End Play Inspection/Adjustment

      • 203

        Counter Balancer

      • 203

        Pump Shaft

      • 203

        Pump Shaft Oil Seal Installation

      • 204

        Crankshaft, Counter Balancer and Oil Pump Installation

      • 204

        To Assemble the Crankcase

      • 205

        Water Pump Mechanical Seal Installation

      • 205

        Water Pump Mechanical Seal Removal - Engine Installed

      • 208

        Piston Installation

      • 209

        Cylinder Installation

      • 210

        Cylinder Head Installation

      • 211

        Cam Chain/Camshaft Installation

      • 212

        Camshaft Installation - Timing Method

      • 213

        Method 1 - Camshaft Timing with Stator Removed

      • 214

        Camshaft Installation - Timing Method 2

      • 215

        Method 2 Camshaft Timing Using Flywheel TDC Mark

      • 216

        Cam Chain Tensioner Installation

      • 216

        Stator, Flywheel and Starter Drive Installation

      • 218

        Oil Pipes

      • 218

        Rocker Shaft/Rocker Arm Assembly Installation

      • 218

        Thermostat Installation

      • 219

        Engine - Sealed Recoil

      • 219

        Recoil Disassembly/Inspection

      • 220

        Recoil Assembly

      • 220

        To Install a New Spring

      • 220

        To Reinstall an Old Spring

      • 222

        Spark Plug Fouling - 2 Stroke Engine

      • 222

        Spark Plug Fouling - 4 Stroke Engine

      • 223

        2 Stroke Engine Troubleshooting

    • 224

      Starter Motor

      • 225

        4 Stroke Engine Troubleshooting

      • 227

        Piston Damage Checklist - 2 Stroke Engines

      • 228

        Fuel System/Carburetion

      • 230

        Fuel System/Carburetion - 1996 Specifications

      • 230

        Jetting Compensation for Altitude and Temperature - 1996 Models

      • 230

        Jetting Guidelines

      • 234

        Fuel System/Carburetion - 1997 Specifications

      • 234

        Jetting Compensation for Altitude and Temperature (1997)

      • 235

        1998 Trail Boss W98AA25C (Engine -EC-25PFE-10) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 235

        Fuel System/Carburetion - 1998 Specifications

      • 236

        1998 Trail Blazer W98AA25C (Engine -EC-25PFE-11) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 237

        XPRESS 300 W98CA28C (Engine -EC-28PFE-12) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature

      • 238

        XLPORER 300 W98CC28C (Engine -EC-28PFE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature

      • 239

        1998 XLPORER 400 W98CC38C (Engine -EC-38PFE-06) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 240

        1998 Sport 400 W98BA38C (Engine - EC-38PLE-07) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 241

        1998 Scrambler 400 W98BC38C (Engine - EC38PLE-09) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 242

        Magnum 2 X 2 W98AA42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature

      • 243

        Magnum 4 X 4 W98AC42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature

      • 244

        1998 Scrambler 500 W98BC50A (Engine - EH50PLE-04) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 245

        Sportsman 500 W98CH50A (W90CH50AB) (Engine - EH-50PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature

      • 246

        1998 Big Boss 500 6X6 W98AE50A (Engine - EH50PLE-06) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature

      • 247

        Fuel System/Carburetion - Jet Part Numbers

      • 248

        Oil Tank and Fuel Tank Assembly - Gen II (Except Magnum)

      • 249

        Fuel Tank Assembly (Magnum)

      • 250

        Oil Tank and Fuel Tank Assembly (Gen III Typical)

      • 251

        Fuel Tank Assembly (Gen IV)

      • 252

        Fuel Tank Assembly - 500 Models (1997 Xplorer 500, Sportsman 500)

      • 253

        Fuel Flow Diagrams

      • 254

        Mikuni VM Carburetor Exploded Diagram

      • 255

        Carburetor Function

      • 255

        Float System

      • 256

        Air/Fuel Mixture Ratio

      • 256

        Component Functions

      • 256

        Pilot Air Screw

      • 256

        Pilot Jet

      • 257

        Jet Needle

      • 257

        Needle Jet

      • 257

        Throttle Opening Vs. Fuel Flow

      • 258

        Main Jet

      • 258

        Throttle Valve

      • 259

        Starter System - Closed Throttle

      • 260

        Pilot System (0-3/8 Throttle)

      • 261

        Slide Cutaway (1/8-3/8 Throttle)

      • 262

        Jet Needle/Needle Jet (3/8-3/4 Throttle)

      • 263

        Main System (3/4 to Full Throttle)

      • 264

        Component Effect Vs. Throttle Opening

      • 264

        Mikuni VM Fuel Delivery Chart

      • 265

        Mikuni VM Carburetor System Components

      • 265

        Venting Systems

      • 266

        Mikuni BST 34 Carburetor Exploded View

      • 267

        Venting Systems (Mikuni CV)

      • 268

        Mikuni CV Carb Operation

      • 269

        Pilot (Idle and Slow) Systems

      • 269

        Starter System (Choke or Enrichment)

      • 270

        Float System (Mikuni CV)

      • 270

        Main System (Mikuni CV)

      • 271

        Magnum Fuel Tank Removal

      • 272

        Carburetor Removal ( Mikuni CV)

      • 273

        Carburetor Disassembly - Mikuni CV

      • 276

        Carburetor Cleaning - Mikuni CV

      • 279

        Carburetor Assembly - Mikuni CV

      • 280

        Carburetor Assembly/Adjustment - Mikuni CV

      • 280

        Float Height Adjustment (Mikuni CV)

      • 282

        CV Carburetor Installation

      • 283

        Fuel Level (Mikuni CV)

      • 283

        Inlet Needle and Seat

      • 283

        Needle and Seat Pressure Test Mikuni CV

      • 284

        Float Bowl Draining

      • 286

        Fuel Pump Exploded View

      • 287

        Fuel Pump Disassembly

      • 287

        Fuel Pump Inspection/Assembly

      • 287

        Fuel Pump Testing

      • 288

        Fuel Starvation/Lean Mixture

      • 288

        Fuel System/Carburetion Troubleshooting

      • 288

        Poor Idle

      • 288

        Rick Mixture

      • 289

        Erratic Idle

      • 289

        Idle too Low

      • 290

        Body and Steering

      • 292

        Body and Steering - Torque Specifications and Special Tools

      • 293

        1996 Body Styles

      • 293

        1997 Body Styles

      • 293

        1998 Body Styles

    • 293

      Body Styles

      • 295

        Body Assembly Exploded View (Gen II - Typical)

      • 296

        Cover/Panel Removal (Gen II - Typical)

      • 297

        Cover/Panel Removal (Gen III - Typical)

      • 298

        Cover/Panel Removal (Gen IV - Typical)

      • 299

        Body Assembly Exploded View (Gen III - Typical)

      • 300

        Body Assembly Exploded View (Gen IV - Typical)

      • 301

        Body Assembly Exploded View (Gen IV - Headlight Pod)

      • 302

        Headlight Pod Service (Gen IV Typical) - Disassembly

      • 303

        Headlight Pod Service (Gen IV Typical) - Installation

      • 304

        Side Panel Removal (Gen IV - Typical)

    • 305

      Toe Alignment

      • 306

        Toe Alignment - Method 2

      • 307

        Typical Steering Assembly, Exploded View, Trail Boss 250

      • 308

        Steering Assembly, Exploded View, 2X4 Models (Except Trail Boss 250)

      • 309

        Steering Assembly, Exploded View, 4X4 and 6X6 Models

      • 310

        A-Arm Replacement

      • 310

        Rear Axle Bend

      • 310

        Steering Stop Adjustment

      • 311

        Rear Drive Axle, Hub and Wheel Assembly, - 2X4 and 4X4 (Except Sportsman 500)

      • 312

        Concentric Swingarm Rear Axle Assembly, Exploded View - 1998 Scrambler 400/500

      • 313

        Concentric Swingarm Exploded View 1998 Scrambler 400/500

      • 314

        Rear Drive Axle, Hub and Wheel Assembly - Shaft Drive Models

      • 315

        Rear Strut Stabilizer, 6X6 Models

      • 316

        Rear Swing Arm Weldment, 6X6 Models

    • 318

      Swing Arm and Rear Suspension Exploded View

    • 319

      Swing Arm Removal

    • 320

      Swing Arm Removal/Inspection

    • 321

      Swing Arm Assembly/Installation

    • 322

      Concentric Swingarm Removal/Disassembly

    • 323

      Concentric Swingarm Assembly/Installation

      • 324

        Strut Assembly - 400L AWD, Magnum AWD

      • 325

        Front Strut Cartridge Replacement

    • 325

      Front Strut Weldment Replacement

      • 325

        Strut Assembly - 2X4 Models

      • 326

        Front Strut Removal

      • 326

        Front Strut Service

      • 327

        Front Strut Installation

    • 328

      Front Strut Ball Joint Replacement

      • 329

        2X4 Front Hub Disassembly/Inspection

      • 329

        2X4 Hub Bearing Service

      • 330

        2X4 Front Hub Assembly

      • 331

        2X4 Front Hub Installation

      • 331

        2X6 Hub Bearing Service

      • 332

        Fox Shock Service

    • 333

      Foxtm Shock Service

    • 339

      Fox Shock Standard Valving Chart

    • 340

      1996 Optional Suspension Springs

    • 341

      1997 Optional Suspension Springs

    • 342

      1996 Paint Codes

    • 343

      1997 Paint Codes

    • 344

      Clutches

    • 346

      Clutch - Specifications

    • 346

      Clutch - Special Service Tools and Supplies

    • 346

      1996 Productoin Specifications

    • 346

      1996 Clutch Recommendations For Altitude

    • 347

      1997 Production Specifications

    • 347

      1997 Clutch Recommendations For Altitude

    • 348

      1998 Production Specifications

    • 348

      1998 Clutch Recommendations For Altitude

• 349

  Chapter 6

  • 349

    Shift Weights

    • 351

      Drive Clutch Spring Specifications

    • 352

      Clutches Overview

    • 352

      Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM

    • 353

      Drive Clutch Operation

    • 353

      Driven Clutch Operation

    • 353

      PVT System Indroduction

    • 354

      Clutch Maintenance

      • 354

        PVT Maintenance/Inspection

      • 354

        PVT Overheating

      • 354

        PVT Sealing and Ducting Components - Type I

      • 355

        PVT Sealing and Ducting Components - Type II

      • 356

        PVT Sealing and Ducting Components - Type III

      • 356

        PVT Sealing and Ducting Components - Type IV

      • 358

        Typical PVT Disassembly

    • 359

      PVT Assembly

    • 361

      Drive Belt Removal/Inspection

    • 361

      Drive Belt Tension

      • 362

        Clutch Alignment /Offset

      • 363

        Driven Clutch Disassembly

    • 365

      Driven Clutch Assembly

      • 367

        Drive Clutch - Springs Specifications Table

      • 368

        Drive Clutch Inspection

      • 368

        Moveable Sheave Bushing Inspection

      • 368

        Spider Removal

      • 369

        Drive Clutch Disassembly

      • 369

        Roller, Pin and Thrust Washer Inspection

    • 371

      Drive Clutch Assembly

      • 372

        Clutch Bushing Removal and Installation

      • 372

        Drive Clutch Moveable Sheave - Bushing Removal

      • 372

        Polaris Kit PN 2871226

      • 373

        Drive Clutch Moveable Sheave - Bushing Installation

      • 374

        Drive Clutch Cover - Bushing Removal

      • 375

        Drive Clutch Cover - Bushing Installation

      • 376

        Driven Clutch Moveable Sheave - Bushing Removal

      • 378

        Driven Clutch Moveable Sheave - Bushing Installation

    • 380

      Engine Braking System (EBS)

    • 380

      One-Way Clutch

    • 380

      Driven Clutch Spring

    • 380

      High Elevation Setup

    • 381

      EBS Exploded View

    • 382

      Drive Clutch Disassembly - EBS

    • 382

      Drive Belt Removal - EBS

    • 382

      One-Way Clutch Inspection (Drive Clutch)

    • 383

      Inspection of Moveable Sheave Bushing

    • 384

      Driven Clutch Disassembly - EBS

    • 384

      One-Way Clutch Preliminary Inspection (Driven)

    • 385

      Roller Pin Disassembly

    • 387

      Operation Guidelines for EBS Clutches

    • 388

      Clutches Troubleshooting

    • 390

      Final Drive

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Polaris 1998 Sportsman 500 Service Manual (505 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 47.62 MB

Table of Contents

• 1

  Table of Contents

• 5

  Quick Reference Data

  • 5

    Tire Inflation Pressure

  • 5

    Recommended Lubricants, Fluids and Capacities

  • 5

    Recommended Capacities

  • 6

    Maintenance and Tune-Up Torque Specifications

  • 6

    Maintenance and Tune-Up Specifications

  • 6

    Replacement Bulbs

• 7

  General Information

• 7

  Manual Organization

• 7

  Chapter One

  • 8

    Notes, Cautions and Warnings

  • 8

    Safety First

  • 9

    Cleaning Parts

  • 9

    Handling Gasoline Safely

  • 10

    Service Hints

  • 12

    Torque Specifications

  • 12

    Fas Teners

    • 13

      ISO Metric Screw Threads

    • 13

      Machine Screws

    • 13

      Nuts

    • 14

      Self-Locking Fasteners

    • 14

      Washers

    • 14

      Cotter Pins

    • 14

      Circlips

  • 15

    Lubricants

  • 15

    Engine Oil

  • 16

    Threadlocking Compound

  • 16

    RTV Gasket Sealant

    • 16

      Expendable Supplies

    • 16

      Grease

    • 17

      Serial Numbers

    • 18

      Warning and Information Labels

    • 18

      Basic Hand Tools

    • 18

      Screwdrivers

    • 18

      Pliers

    • 19

      Locking Pliers

    • 19

      Circlip Pliers

    • 19

      Box, Open-End and Combination Wrenches

    • 19

      Adjustable Wrenches

    • 20

      Socket Wrenches

    • 20

      Allen Wrenches

    • 20

      Torque Wrench

    • 20

      Impact Driver

    • 21

      Precision Measuring Tools

    • 21

      Feeler Gauge

    • 21

      Vernier Caliper, Dial Caliper and Digital Electronic Caliper

    • 21

      Outside Micrometers

    • 22

      Micrometer Range

    • 22

      How to Read a Micrometer

    • 22

      Standard Inch Micrometer

    • 23

      Decimal Place Values

    • 24

      Vernier Inch Micrometer

    • 25

      Standard Metric Micrometer

    • 26

      Micrometer Accuracy Check

    • 28

      Proper Care of a Micrometer

    • 28

      Cylinder Bore Gauge

    • 28

      Small Hole Gauges

    • 29

      Telescoping Gauges

    • 29

      Multimeter

    • 29

      Voltage

    • 30

      Resistance

    • 30

      To Calibrate an Analog Ohmmeter

    • 30

      Continuity Test

    • 30

      Amperage

    • 31

      Special Tools

    • 31

      Fabricating Tools

    • 31

      Mechanic's Tips

    • 31

      Removing Frozen Nuts and Screws

    • 32

      Bearing Replacement

    • 32

      Bearing Removal

    • 32

      Removing Broken Screws and Bolts

    • 34

      Bearing Installation

    • 34

      Shrink Fit

    • 35

      Seals

    • 36

      Storage

    • 36

      Selecting a Storage Area

    • 36

      Preparing Vehicle for Storage

    • 37

      After Storage

    • 37

      Model Year and Number

    • 38

      General Dimensions

    • 38

      Vehicle Weight (DRY)

    • 38

      Decimal and Metric Equivalents

    • 39

      General Torque Specifications

    • 39

      Conversoin Tables

    • 40

      Technical Abbreviations

    • 41

      Metric Tap and Drill Sizes

• 42

  Troubleshooting

• 42

  Operating Requirements

• 42

  Chapter Two

  • 43

    Starting a Cold Engine

  • 43

    Starting the Engine

    • 43

      Troubleshooting Instruments

    • 44

      Starting a Flooded Engine

    • 44

      Starting a Warm or Hot Engine

    • 44

      Starting Difficulties

    • 45

      Engine Fails to Start (Spark Test)

  • 46

    Engine Is Difficult to Start

  • 47

    Engine Compression

  • 47

    Engine Starting System

    • 47

      Poor Idle Speed Performance

    • 47

      Poor Medium - and High-Speed Performance

  • 48

    Charging System

    • 48

      Starter Troubleshooting

    • 49

      Ignition Coil Test

    • 49

      Ignition System

    • 49

      Ignition System Precautions

    • 49

      Switch Test

  • 50

    Ignition System

    • 51

      Electronic Throttle Control Switch Testing

    • 52

      Engine Detonation

    • 52

      Engine Overheating

    • 52

      Engine Preignition

    • 52

      Fuel System

    • 53

      Cylinder Leakdown Test

    • 53

      Engine Noises

    • 53

      Piston Seizure

    • 53

      Power Loss

    • 54

      Engine Operating Speed too High

    • 54

      Engine Speed Erratic During Speed or Load Changes

    • 54

      Low Engine Operating Speed

    • 54

      Power Train

    • 55

      Drive Belt Not Operating Smoothly in Primary Sheave

    • 55

      Erratic Shifting

    • 55

      Glazed Drive Belt

    • 55

      Steering

    • 56

      Disc Brake Troubleshooting

    • 57

      Brakes

    • 57

      Frame Noise

    • 57

      Generally Poor or Unpredictable Handling

    • 57

      Loose Steering

    • 58

      Electrical Specifications

    • 59

      Lubrication, Maintenance and Tune-Up

    • 59

      Pre-Ride Checklist

    • 61

      Tire Inspection

    • 61

      Tire Pressure

    • 61

      Tires and Wheels

    • 62

      Battery

    • 62

      Rim Inspection

    • 62

      Safety Precautions

    • 63

      Battery Removal/Installation

    • 63

      Electrolyte Level Check

    • 64

      Cleaning, Inspection and Adding Water

    • 65

      Battery Testing

    • 66

      Charging

    • 66

      New Battery Installation

    • 67

      Battery Electrical Cable Connectors

    • 67

      Engine Oil Level Check

    • 67

      Periodic Lubrication

    • 68

      Engine Oil and Filter Change

    • 70

      Engine Oil Pressure Test

    • 71

      Transmission Oil Change

    • 71

      Transmission Oil Level Check

    • 72

      Front Gearcase Oil Change

    • 72

      Front Gearcase Oil Level Check

    • 73

      Grease Service

    • 74

      Front Hub Oil Change

    • 74

      Front Hub Oil Level Check

    • 76

      Control Cable Lubrication

    • 76

      Disc Brake System Inspection

    • 76

      Drive Belt Inspection

    • 76

      Periodic Maintenance

    • 77

      Disc Brake Fluid Level Check and Fill

    • 77

      Disc Brake Hoses

    • 78

      Auxiliary Brake Testing and Adjustment

    • 78

      Throttle Cable/Electronic Throttle Control Adjustment

    • 79

      Throttle Cable Adjustment

    • 80

      Air Filter Element

    • 81

      Coolant Inspection

    • 82

      Coolant Change

    • 84

      Exhaust System

    • 85

      Fuel Filter Replacement

    • 85

      Fuel Hose Inspection

    • 85

      Steering System and Front Suspension Inspection

    • 86

      Front Wheel Toe-Out

    • 87

      Front Hub Wheel Bearings

    • 87

      Nuts, Bolts and Other Fasteners

    • 87

      Rear Suspension

    • 87

      Wire Harness, Control Cables and Hose Lines

    • 88

      Body Fasteners

    • 88

      Fuel Tank and Lines

    • 88

      Recoil Starter

    • 88

      Unscheduled Inspection and Maintenance

    • 89

      Valve Clearance Measurement

    • 90

      Valve Clearance Adjustment

    • 91

      Cam Chain Adjustment

    • 91

      Spark Plug Heat Range

    • 91

      Spark Plug Removal

    • 92

      Gapping and Installing the Spark Plug

    • 92

      Reading Spark Plugs

    • 93

      Carbon-Fouled

    • 93

      Gap Bridging

    • 93

      Normal Condition

    • 93

      Oil-Fouled

    • 94

      Spark Plug Condition

    • 95

      Adjusting Ignition Timing

    • 95

      Checking Ignition Timing

    • 95

      Preignition

    • 95

      Worn out

    • 96

      Carburetor Idle Mixture Adjustment

    • 97

      Idle Speed

    • 97

      Maintenance and Lubrication Schedule

    • 98

      Recommended Lubricants and Fluids

    • 99

      Capacities

    • 100

      Engine Cooling

    • 100

      Engine Principles

    • 100

      Engine Top End

    • 101

      Four-Stroke Operating Principles

    • 102

      Engine Lubrication

    • 102

      Servicing the Engine in the Frame

    • 105

      Cylinder Head Cover

    • 105

      Rocker Arm Assembly

    • 107

      Rocker Arm

    • 109

      Camshaft Removal

    • 110

      Camshaft Inspection

    • 112

      Automatic Compression Release Mechanism Testing

    • 113

      Camshaft Installation

    • 116

      Cylinder Head Removal

    • 117

      Cylinder Head Inspection

    • 118

      Cylinder Head Installation

    • 119

      Valves and Valve Components

    • 120

      Solvent Test

    • 120

      Valve Removal

    • 121

      Valve Inspection

    • 122

      Valve Troubleshooting

    • 123

      Valve Installation

    • 124

      Valve Guide Replacement

    • 124

      Valve Lapping

    • 125

      Cylinder Block Removal

    • 126

      Cylinder Block Inspection

    • 128

      Cylinder Block Installation

• 128

  Spec Ial Tools

  • 130

    Piston and Piston Rings

  • 130

    Piston Removal

  • 131

    Piston Inspection

  • 133

    Piston Pin Inspection

  • 133

    Piston Clearance

  • 134

    Piston Installation

  • 134

    Piston Ring Inspection and Removal

  • 136

    Piston Ring Installation

  • 137

    Camshaft Chain and Sprockets Removal

  • 138

    Camshaft Chain and Sprockets Inspection

  • 139

    Camshaft Chain and Sprockets Installation

  • 139

    Camshaft Chain Wear

  • 140

    Break-In Procedure

  • 140

    General Engine Specifications

  • 140

    Engine Lubrication System

  • 141

    Engine Top End Tightening Torque Specifications

  • 141

    Engine Top End Specifications

  • 143

    Engine Lower End

  • 143

    Engine

  • 144

    Engine Removal

  • 147

    Flywheel and Stator Plate Removal

  • 149

    Flywheel and Stator Plate Installation

  • 150

    Recoil Starter Removal/Installation

  • 150

    Recoil Starter Disassembly and Starter Rope Removal

  • 150

    Recoil Starter Inspection and Assembly

  • 152

    Crankcase

  • 153

    Crankcase Separation

  • 156

    Crankcase Inspection

  • 156

    Crankshaft Seal Replacement

  • 157

    Crankcase Bearing Replacement

• 157

  Seals

  • 161

    Water Pump Mechanical Seal and Bearing Replacement

  • 162

    Crankcase Assembly

  • 168

    Crankshaft Inspection

  • 169

    Crankshaft and Balancer

  • 169

    Balancer Shaft Inspection

  • 169

    Shaft End Float Measurement and Shim Selection

  • 171

    Crankshaft End Play

  • 172

    Balancer Shaft End Play

  • 174

    Oil Pump Removal/Disassembly

  • 174

    Oil Pump Inspection

  • 177

    Oil Pump Assembly/Installation

  • 178

    Oil System One-Way Check Valve

  • 179

    Oil System One-Way Check Valve Break-In Procedure

  • 180

    Engine Lower End Torque Specifications

  • 180

    Engine Lower End Specifications

  • 181

    Carburetor Operation

  • 182

    Carburetor Removal/Installation

  • 183

    Carburetor Disassembly

  • 184

    Mikuni Carburetor 34 MM

  • 189

    Carburetor Cleaning and Inspection

  • 192

    Carburetor Tests and Adjustments

  • 192

    Inlet Valve Seat Inspection

  • 192

    Float Level Height Adjustment

  • 193

    Jet Needle Adjustment

  • 193

    Main Jet Replacement

  • 194

    Throttle Cable Replacement

  • 194

    Starting Enrichment (Choke) Cable Removal/Installation

  • 196

    Fuel Tank Removal/Installation

  • 197

    Fuel Shutoff Valve

  • 198

    Air Filter Air Box Removal/Installation

  • 198

    Fuel Pump Testing

  • 202

    Fuel Pump Removal/Installation

  • 203

    Fuel Pump Disassembly/Assembly

  • 203

    Carburetor Specifications

  • 204

    Cooling Systems

  • 204

    Polaris Variable Transmission (PVT) Air Cooling System

  • 205

    PVT Cooling System

  • 205

    Clutch Outer and Inner Cover Ducting

  • 205

    Clutch Outer Cover Removal/Installation

  • 206

    Clutch Inner Cover Removal/Installation

  • 208

    Engine Cooling System

  • 209

    Liquid Cooling System (Typical)

  • 210

    Hoses and Hose Clamps

  • 210

    Engine Gaskets/Seals

  • 211

    Radiator Assembly

  • 211

    Cooling System Inspection

  • 211

    Radiator Removal/Installation

  • 214

    Radiator Inspection

  • 215

    Cooling Fan Removal/Installation

  • 217

    Thermostat Removal/Installation

  • 218

    Temperature Sensors

  • 218

    Cooling System Specifications

  • 219

    Clutch/Drive Belt System

  • 219

    Drive Unit

  • 221

    Drive Pulley

  • 221

    Fixed and Sliding Pulley Halves

  • 221

    Drive Pulley Spring

• 221

  Eng Ine no Ises

  • 222

    Driven Pulley

  • 222

    Centrifugal Weight Levers

  • 222

    Release Spring

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