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1999 Polaris 500 Diesel Service Manual
By
colin james, in Polaris ATV Forum
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Similar Topics
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By Sonders
It appears that the Service Manual thread at top of forum is dead as all the links no longer work. I'm actually looking for service manual for a 2000 KVF300 Prairie that I just picked up. Does anybody have link to one that they can share, or know where I can find one? Thanks in advance for any help.
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By Flipper Tiffany Roper Jones
All I have been through everything. Bought brand new.
Throttle safety switch
Cam and rockers
ECM
Carborator
Stator
Fuel safety switch
Battery
Everything every forum has spoken of I've bought sealed airbox completely tight unplugged black wire on trans. I have literally done everything in the book.Checked oil today full of gas anyone no anything what might b wrong. Next I'm taking head off and making sure valves seat any ideas.
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By Christian Smith
Recently bought a Polaris 425 Xpedition. Main issue is that the quad randomly misfires sometimes. ONLY does it at idle. Everything sounds good. What should I look for? Haven't checked the plug, seems a bit hard to get to, not sure. Headlights flicker at idle as well, is this a sign of a weak stator? Help?
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By Ryann Racho
So Id say about 2 years back I bought a 2013 Polaris Sportsman 500 H.O. off of my uncle. It ran perfectly, nothing wrong at all. I usually go mudding with it or just ride trails with buddies. So as you would assume, the quad is quite dirty from sitting for a few weeks.
STUTTERING PROBLEM: I noticed one day out of nowhere that in high gear at 15-20 MPH, I was already maxed out at 4500-5000 RPM It would get to 15-20 mph, max out on rpms and start sputtering. It sounded like it was basically acting like it couldn’t go any faster than this.
IDLING PROBLEM: I was fucking with the carberator the other day maybe thinking that is causing my sputtering, and now my idle will shoot up to 2600 on start usually, then I will turn the throttle adjustment down to the normal 1400. The rpms with then fluctuate 10-30 rpms back and forth repeatedly, it will then run for about another 30-60 seconds and the RPMs will slowly drop to about 900-1000 RPM and stall out. I replaced the carburetor and everything seems to be working perfect on that, no leaks and what not but it’s still acting strange. Also, I’ve noticed that when looking into the Electronic Throttle Control that two plates that aren’t supposed to touch have to be WAY past touching to even try to fire up. Even when set at a wide open throttle like that, I still have to give it some throttle to get it to fire up.
Here is what I have done so far:
Checked the belt and clutch
Changed out spark plug (Last one was covered in carbon)
Cleaned the intake and air box
Replaced the carburetor
Replaced the inline fuel filter
Checked that all lines on carburetor are connected into the right spots
Checked If intake boot was cracked (Not from what I can see)
Unhooked and reattached new carburetor (About 4-5 times)
Cleaned battery terminals and battery off
Shut on and off Gas Line Cutoff Valve
My next thoughts are that maybe the TPS is fucked up or maybe the Spark Arrestor is plugged with mud. I was thinking tomorrow to purge the exhaust and also check the ohms output on the TPS.
ANY HELP IS GREATLY APPRECIATED. I HAVE BEEN BATTLING THIS FOR WEEK AND REALLY WANT TO GO RIDING. THANK YOU!
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By stinky
I have an Outlaw 110 that will struggle to turn the engine over. Jump starting doesn't help other than the battery will drain LONG before the bike eventually starts, so is required. If you keep messing with it long enough it will eventually magically begin to crank fine and sometimes finally start. Once we finally get the bike to start and warm it up thoroughly, it will turn over and start just fine the rest of the day like nothing ever happened... next day it won't turn over again. Internet research has found lots of people saying they replaced starters, starter clutch, wiring, etc. but with only about 50/50 success rate for their particular problems... and I never found anybody describing a problem like mine, so I'm looking for advice/experience. Would rather not just start blindly throwing parts at it. Does anybody have any thoughts/ideas?
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By mrfartsalot
i have a 2001 suzuki quadmaster 500 4x4 that the primary cvt clutch is rusted on any ideas on how to get it off i want to try to reuse it if possible.
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By Paul Maple
I have a 1999 Sportsman 500, it was running fine, than started to lose power in the winter, I adjusted the idle screw and away I went, than a few weeks ago it died, I have found that i am flooding the engine, compression was at 70PSI and due to the compression release mech. i assume i am good as it compared to the same PSI on a 2000 sportsman 500 i have. i cannot start the atv unless i go full throttle and it starts an runs for about 30 sec than dies, again it is flooded. i ordered a new carb off ebay as i could get one for around $40. put that in same issue, i have checked the timing, (good), valves out of adjustment i adjusted to .006 still same issue, i have found the exhaust lobe and rocker arm to have some wear, i have ordered new ones, but am looking for any other input in this area as well. would the exhaust cam and rocker arm cause the engine to flood? i have used a bore scope and the piston liner has good cross hatching still? any input would be great.
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By colin james
View File 1996-2000 Polaris Sportsman 335/500 Service Manual
This is the factory service manual for the polaris sportsman 335 & 500.
You can download the section you need or download all of the chapters for the complete manual
Submitter colin james Submitted 10/19/2018 Category Polaris ATV
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By colin james
This is the factory service manual for the polaris sportsman 335 & 500.
You can download the section you need or download all of the chapters for the complete manual
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By colin james
This is the factory service manual for the sportsman 500 6x6.
Download just the chapters you need or can download all chapters to have complete service manual.
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