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Similar Forum Topics
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By oxidized_black
these are what i have in my collection ... always looking for more
1985 - 1995 Polaris All Models service manual
1996 - 1998 Polaris All Models service manual
1996 - 2003 Polaris Sportsman & Xplorer 500 service manual
1996 - 2003 Sportsman 400 & 500 ~ Xplorer 500 service manual
1999 - 2000 Polaris All Models service manual
2001 Polaris 90 service manual
2001 Polaris Scrambler 50 ~ 90 Sportsman service manual
2001 Polaris Sportsman 500HO Parts Manual
2001 Polaris Sportsman 500 Parts Manual
2002 - 2003 Polaris Sportsman 600 & 700 Servive Manual
2002 Polaris Sportsman 700 service manual
2003 - 2005 Polaris Magnum 330 service manual
2003 Polaris Predator 500 service manual
2003 Polaris Predator Parts Manual
2003 Polaris Trail Blazer 250 service manual
2003 Polaris Trail Boss 330 service manual Part I
2003 Polaris Trail Boss 330 service manual Part II
2003 Polaris Trail Boss 330 service manual Part III
2004 Polaris Predator 500 Owner's Manual
2004 Polaris Sportsman Owner's Manual
2005 Polaris 400 & 500 Sportsman service manual
2005 Polaris 700EFI Owner's Manual
2005 Polaris 800EFI Owner's Manual
2005 Polaris Sportsman 400 Parts Manual
2005 Polaris Sportsman 500 Parts Manual
2005 Polaris Sportsman 6x6 Owner's Manual
2005 Polaris Sportsman 700EFI & 800EFI service manual
2005 Polaris Sportsman 800 Twin EFI Parts Manual
2006 - 2007 Polaris Outlaw 500 service manual
2007 Polaris 700 800 800x2 EFI service manual
2007 Polaris Ranger 700EFI 6x6 Parts Manual2007 Polaris Ranger 700 4x4 & 6x6 service manual
2007 Polaris Ranger XP 4x4 service manual
2007 Polaris Sportsman 450 & 500EFI - 500X2EFI service manual
2007 Polaris Sportsman 700 800 - 800EFI service manual
2008 Polaris Sportsman 500EFI & 500x2 service manual
2008 Polaris Ranger 6x6 700EFI Parts Manual
2008 Polaris 800 RZR service manual
2008 Polaris Sportsman 700x2 - 800EFI - 800 Touring service manual
2009 Polaris 850HD EPS service manual
2009 Polaris Outlaw 450 & 525 service manual
2009 Polaris Outlaw 90 service manual
2009 Polaris Predator 50 service manual
2009 Polaris Ranger 2x4 service manual
2009 Polaris Ranger 4x4 Crew service manual
2009 Polaris Ranger 500 2x4 service manual
2009 Polaris Ranger 500EFI 4x4 service manual
2009 Polaris Ranger 500EFI 4x4 service manual
2009 Polaris Ranger 700 4x4 Crew service manual
2009 Polaris Ranger 700 4x4 service manual
2009 Polaris Ranger INTL service manual
2009 Polaris Ranger RZR 170 service manual
2009 Polaris Scramber 500 service manual
2009 Polaris Sportsman 300 & 400HO service manual
2009 Polaris Sportsman 450 & 500X2 service manual
2009 Polaris Sportsman 500 service manual
2009 Polaris Sportsman 6x6 800 service manual
2009 Polaris Sportsman 800EFI & 800EFI service manual
2009 Polaris Sportsman 550XP service manual
2009 Polaris Sportsman 850XP service manual
2009 Polaris Trail Boss - Trailblazer 330 service manual
2010 Polaris Ranger RZR S service manual
2011 Polaris Ranger RZR S service manual
2011 Polaris Ranger RZR SW service manual
2012 Polaris Sportsman 400 service manual
Visit the Polaris service manual Section: https://www.quadcrazy.com/files/category/7-polaris-atv/
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By Jacksonbell
I just went out to start my 2004 polaris sportsman 600 and nothing happened. It didnt have power to the dash and wouldn't turn over. I have no idea why, but it's not the battery because the winch still works. Can anyone help?
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By PolarisRich
I've never done this before but after reading a few thread I decided to check my valves for the first time and to my surprise it was much easier than I thought.
My bike is a 2005 Sp 500 HO.
I first pulled the seat and the right side panel off, and that's it! It wasn't too bad to get at.
Next I pulled the spark plug out and removed both the head cover ( 8-8mm bolts)
[ATTACH]1021[/ATTACH]
then the side cam cover (5-8mm bolts).
[ATTACH]1023[/ATTACH]
Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
[ATTACH]1022[/ATTACH]
Next I turned the engine over with the pull cord untill it was at TDC of the compression stroke.
The best was to tell that your at TDC of the compression stroke is to rotate the engine until the
timing marks are parallel to rocker cover gasket surface.
The cam sprocket locating pin will be facing upward directly in line with the crankshaft to camshaft center line.
Now fine adjust by looking into the timing hole in the recoil cover and line up the upside down "T" on
the flywheel into the center of the hole.
[ATTACH]1023[/ATTACH]
Now using a feeler gauge, slide the .006" (.15mm)blade between the top of the valve and the bottom of the adjuster and adjust accordingly
[ATTACH]1024[/ATTACH]
[ATTACH]1025[/ATTACH]
To adjust, Loosen the locknut (10mm) and check clearance with a feeler guage. Clearance should be .006" (.15mm) for both, intake and exhaust valves. Turn the adjuster with a stubby flat blade screwdriver untill the proper clearance is achieved then tighten the locknut (5.8-7.2 ft. lbs) while holding the adjuster in place with the screwdriver. Re-check the clearance with the feeler guage one last time and re-assemble the covers (72 in.lbs) and plugs.
The only thing that i noticed was that I had to clean and silicone the side cam cover other than that I found the whole process rather simple.
I'd give it a 4 out of 10 on the skill level scale.
I hope this helps!
Thanks Rich
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By Sportsman500guy
I bought a 1996 Sportsman 500 4x4 about a month ago, and I love it. Unfortunately, I've been experiencing a few problems with the high-range gear. The first problem is that the gear selector will intermittently pop out of high and into neutral. This problem will sometimes occur when starting from a stop and sometimes will also occur while at cruising speed. The last time this happened I stopped and put it back into gear, however, as soon as I tried to throttle the machine would die. I turned it on again with no problems put it back into high and it died again. Once again I turned it on with no problems put it into low instead and it worked fine with no problem. I drove in low down the road slowly for a little and then shifted back into high with no issues.
I plan on working on it this weekend and would just like some opinions or feedback from anyone who may have experienced these problems before. I'm very mechanically inclined but im unsure of exactly where to start as this is the first Polaris ATV that I've owned. Any feedback is appreciated and thanks in advance
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