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colin james

2001 Polaris Sportsman 500 6x6 Factory Service Manual

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      View File 1996-2000 Polaris Sportsman 335/500 Service Manual
      This is the factory service manual for the polaris sportsman 335 & 500.
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      Submitter colin james Submitted 10/19/2018 Category Polaris ATV  
    • 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.
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      [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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