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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 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 Steven Alter
I have a 2018 450 and the digital gause has started flashing on an off while driving. The backlit also goes on and off. It is worse when I hit the gas. The battery died a few weeks ago and I jumped it but its been fine until last night. Called the dealer and showed them a vid and they recommend replacing the gauge and its like 600 bucks. The machine has less than 100 hours on it. I would really hate to have to change it out. also the unit sometimes has trouble starting. Any ideas?
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By Ajmboy
Here is the Polaris online parts catalog, looks like you need to register with then first. I haven't used it since I'm not a Polaris owner and don't need any parts right now...
http://parts.polarisind.com/Browse/Browse.asp
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Similar Tagged Content
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By StayTheTrail
Hey everyone!
Ya'll have been so great and welcoming to our new Ambassador program, we wanted to be sure that Quad Crazy was getting info directly from us about the Stay The Trail educational program too.
The program was started in 2003 with the purpose of educating the public about responsible trail use and fostering a sense of stewardship among OHV enthusiasts.
The "Where To Go" section of our website is another great resource for anyone looking for trail info. We host all of the Motor Vehicle Use Maps (MVUM) and overlay them on the Google mapping system. We want this site to be the place you go to for trail maps as you plan a run. The MVUM maps show what trails are open for what types of vehicles. If a trail is not on these maps, it is not an open trail.
We attend events and set up at trailheads throughout the season to ensure that folks are getting the info and education they need to be responsible on public trails. We have posters and brochures that quickly review these guidelines (all of the Etiquette info can also be found on the website).
Very soon, we will have a HUGE announcement about mobile mapping options!
Sam and Matt are going to be around on the forum, keeping everyone updated on what is new with the program and answering questions. Feel free to ask us any questions!
Oh – and don’t forget to follow us on FACEBOOK!
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By nickcapa
Hey Guys and Gals,
My name is Nick, how are ya??
Im 21 years old and i am an Ag Salesman,
I sell Tractors and Impliments such as Massey Ferguson, Fendt, Iseki, Kioti, Polaris and Scag Mowers.
I am currently looking into moving to the US for a few years, Not fussed about where just cant wait to get over there and try something different!
I am hoping for get in contact with anyone who can put me onto someone about work,
anything really, for my Visa.
anyways
hope to hear from you all
have a good one!
Nick
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By LTZRider14
Hello all... My real name is Hank. I love to ride. Mostly like to climb hills and mud ride. I ride with my friend ever day. Because there is nothing to do. I am here because I wanted to join a website where everyone wants to talk about atv and having fun.
Thanks,LTZRider14
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