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I am looking for a free repair manual for a 2003 Polaris sportsman 500 ho atv. all the posts on here lead me noplace thanks fred.

Ok guys be easy got a lady here. Yes blonde, but not dumb:yes: Just got the new starter for the quad and wondering if I "really" need a clutch puller since I have to take both primary and secondary out to access the starter? I don't have one. Has anyone done it without one?? I'm gonna start on this tomorrow am so any and all comments will be appreciated,,,a little nervous bout removing the clutch anyway.....wish me luck!! thanks!!

Do any mods to your atv? Let's hear about it!!!

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

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

i have an 07 sawtooth it goes backwards fine but wont go forward. so i know its the shift fork or the drum. they both look in great shape. i dont have the exrta money what one ussaly goes wrong?

Hi, I'm new to this forum and am in desperate need of help. I recently purchased a 05 polaris sportsman 90. The quads motor runs great. The quad will not accelerate forward. If it does its slow and will eventually pick up speed and then runs unbelievable. It has great power and torque in reverse but couldn't go over a twig in forward. I'm lost, any help would be greatly appreciated. The belt is in good condition and the and drained the trans oil and there is no metal shavings

I have a 400 polaris'04 that when in low it pulls but wont in high

Just asking for those that have or have been around them, how well do the diesels do in the winter months? Are they hard to start or do the glow plugs do a good job? Are they reliable? Any other info from folks that know would be appreciated!! Thanks, Ken

The new cab from Extreme Metal Products includes laminated safety glass windshield with a hand operated windshield wiper, Hard Top with LED dome light, and a cab back. It fits 2010 Polaris Ranger 500 and 800. Windshield: The windshield features laminated safety glass like you car has. This windshield will not scratch. The 16 ga. steel frame is powder coated with a texture black. All the More...

Extreme Metal Products is releasing their new 2010 Ranger Cab back designed to fit the 2010 ROPS only, which ensures a very precise fit. The cab is made from 16 gauge steel and is powder coated texture black to match the ROPS certified cab that now comes standard on the 2010 Polaris Vehicles. The edges are hemmed back twice, making a very smooth and strong side. It attaches to your roll cage More...

Worcester, MA. October 1, 2009 - Curtis Industries, LLC has introduced a new, revolutionary, modular cab system for the 2010 Polaris Ranger utility vehicle available early October. This system allows rapid transformation from a fully enclosed cab to an open-air ride in only 60 seconds. The Curtis Rapid-Convertible System (RCS) allows the user to choose one or all components for maximum More...

2010 Polaris RANGER and RANGER RZR Line Up New Products, More Power and ROPS Certified Cabs Model Year 2010 brings more significant changes to Polaris’ RANGER line up with the introduction of two new utility RANGER Side-by-Sides, increased power to existing models, more redesigns, a RANGER XP with power steering and a faster top speed for RANGER RZR. All 2010 RANGERs and RANGER RZRs also come standard with a ROPS Certified Cab. “With the introduction of two new products, more power for the utility line, the redesigned RANGER CREW and 6x6, and a new top speed for RANGER RZR, the 2010 line up picks up where the 2009 line up left off,” said Matt Homan, vice president and general manager of Polaris’ Off-Road division. “We continue to innovate our RANGER line to offer the most extensive Side-by-Side offering in the industry.” Polaris RANGER 400 New for 2010, Polaris is introducing the value-priced, Midsize RANGER 400 and the company’s first electric vehicle, RANGER EV. Both of these units share the same, smaller, two-seat chassis, that fits in the back of a pickup truck, with many of the hardest working, smoothest riding features of their full-sized counterparts: On-Demand True All-Wheel Drive with VersaTrac, Independent Rear Suspension, heavy duty front end protection, high ground clearance and the longest suspension travel in their class. The RANGER 400, although smaller in stature, delivers on the RANGER promise of “hardest working” with real work capabilities such as 500 lbs of cargo capacity, 1,000 lbs payload and 1,250 lbs. of towing, at an attractive $7,999 MSRP. The RANGER 400’s smaller size, 455cc high output, carbureted engine and value price make it an attractive work partner for hunting, farming, maintaining acreage or doing chores around the property. It boasts 29 horsepower and a top speed of 40 mph offering the rider plenty of get-up-and-go to ride to that favorite hunting spot, haul feed to livestock or just take a leisurely ride down the trail. Its On-Demand True All-Wheel Drive ensures it can tackle muddy pastures or rutted, rocky hunting trails, while the VersaTrac ensures you don’t tear up the grass. With a full-line of PURE Polaris products including Lock & Ride accessories, cabs, plows and a speed-regulating, Speed Key, the RANGER 400 can be outfitted to get any job done. To complement its hard work ethic, the RANGER 400 has smoothest riding features such as Independent Rear Suspension, long suspension travel and high ground clearance to ensure a smooth ride and less fatigue on the operator and passenger, making it a true “Hardest Working, Smoothest Riding” Midsize RANGER. Polaris RANGER EV Sharing the same chassis as the RANGER 400, the all-new RANGER EV electric Side-by- Side is a first for Polaris. The unit features the largest battery pack in the industry (11.5 kilowatts) and has the longest range of any electric Midsize. Built for clean and quiet operation, and full of hardest working, smoothest riding features, the RANGER EV is perfect for hunters and homeowners with acreage. With its 30 horsepower electric motor, 35-45 mile range, 25 mph top speed and two hours of riding time between charges, the RANGER EV will transport hunters and their gear to and from their hunting site with fewer disturbances to game. The unit also features a three modes; High for speed, Low for towing and hauling, and Max for maximum range. For harsh terrain, such as muddy fields on the way to fix the fence or trails full of rocks and stumps leading to the tree stand, the RANGER EV features On-Demand True All-Wheel Drive. For more sensitive terrains and a better turning radius, RANGER EV has VersaTrac with one-wheel, rear-wheel drive to prevent damage and also better navigate tight areas often encountered in the woods. The RANGER EV has a 500 lb. Lock & Ride cargo box with 1,250 lb. towing and 1,000 lb. total payload making hauling hunting gear or game a breeze; and the model’s exclusive 48-volt, AC Induction motor provides high performance with low maintenance and can be charged using a standard 110 vac outlet. For quick charges between rides, PURE Polaris is offering a quick charge kit for RANGER 400 to get you back on the trails. In 2009, Polaris introduced the ruggedly re-engineered RANGER that was the hardest working and smoothest riding RANGER EVER built, and introduced the new RANGER HD, the ultimate heavy-duty utility vehicle with a self leveling rear suspension and power steering. This year, the company powered up the RANGER 4x4 (now called RANGER 500 H.O.) with a 500 H.O engine and added an 800 EFI engine across the rest of the line. The RANGER 4x4 gets a 13 percent power increase with the 500 H.O. engine, and the RANGER XP (now called RANGER 800 XP) receives a 15 percent power upgrade with the addition of the 800 twin EFI power plant. The 800cc engine also has been added to the RANGER 800 HD, RANGER 800 CREW and RANGER 800 6x6 solidifying the “Hardest Working” RANGER promise. Along with the power boost, Polaris has added a RANGER 800 XP model with Polaris’ exclusive electronic power steering with variable assist. The system allows for one-finger steering at low speeds and eliminates feedback at high speeds so the operator can work longer and enjoy the ride. Polaris also expanded the work, ride and improved ergonomics from the 2009 RANGER XP and introduced Dual A-arm front suspension to the six-passenger RANGER 800 CREW and RANGER 800 6x6. To create an exterior that could handle the nastiest work and most extreme riding conditions, the models offer the most-armored front end ever designed to protect vital components such as the radiator, cooling system and front differential. The front headlights were inset for added protection from rocks and branches, and the redesigned bumper with a heavy-duty bash plate offers dedicated vehicle tie down points, massive central tow hook and inset tow hook cage for additional front differential protection. For working at night or to get the hunting spot before daybreak, the vehicles offer auxiliary light mounting holes on the front bumper and bosses already installed for optional Halogen/LED distance headlights. The RANGER 800 CREW and 6x6 work harder and are easier on the operator due to improved and thoughtful ergonomics designed to let the operator work longer and enjoy a better ride. The new models feature more seat and leg space including two-inches more for back-seat passengers on the RANGER 800 CREW, reoriented gas and brake pedal for improved operator comfort, new angled-back seat and a relocated brake lever for easy operation inside and outside of the vehicle. Polaris also redesigned the steering wheel for better steering with gloves and added standard tilt steering with the highest range of motion for maximum comfort. Along with tilt steering, the new models have a 50 percent easier steering effort which helps maneuverability in tight areas such as work sites or woods. RANGER 800 6x6 also is furnished with a new a new, truck-like job box between the cargo box and cab. The cargo box is rated for 1,250 pounds, while the job box handles an extra 250 pounds, and the boxes are Lock & Ride capable. To make the smoothest ride in the industry even smoother, Polaris outfitted the new RANGER 800 CREW and 6x6 with exclusive adjustable Dual A-Arm front suspension in addition to its legendary smooth independent rear suspension. Exclusive to RANGER line, the RANGER 800 CREW features motion ratio and preload suspension adjustment front and rear while the RANGER 800 6x6 offers Independent Rear Suspension with motion ration adjustability on all six wheels. The new Dual A-Arm suspension has two upper shock mounting points for each wheel giving a motion ratio adjustment that dramatically increases the stiffness of suspension. The preload adjustment, available on each wheel, increases the initial spring compression for a 30 percent stiffer ride when needed. The new suspension allows for the maintenance of ground clearance (12 in/30.5 cm) and suspension travel (9.6 in/24.5 cm front, 9 in/22.9 cm rear) when carrying heavier loads and using accessories such as plows, cabs and sprayers for work applications. It also allows for easier use of after-market suspension packages. To combat ruts, stumps and rocks, the new RANGERs also offer anti-kickback steering that reduces feedback over bumps and makes the vehicle steerable with one hand. While the 2010 RANGER utility line works harder, the 2010 RANGER RZR line plays harder with even more RZR sharp performance. Last model year, Polaris introduced the RANGER RZR S, the ultimate, pure-sport Side-by-Side built for the desert, dunes and open spaces to complement the 50-inch, trail-capable RANGER RZR. For 2010, RANGER RZR achieves a new top speed of 60 mph and both units feature a ROPS certified cab. Polaris also will offer a variety of Limited Edition models for their 2010 line up. On the utility side, the RANGER 800 XP Limited Editions include Pearl White, Navy/Sandstone and a Browning Edition. The RANGER 800 CREW will be available in Sandstone Metallic. RANGER RZR Limited Editions include Tequila Gold and Turbo Silver, and Orange Madness for RANGER RZR S. RANGER 800 HD - Long Haul, Heavy Duty Utility Vehicle New 800cc EFI engine Hardest Working Features 46 HP, 800 EFI Engine 53 MPH/85.3 km top speed Full instrumentation On Demand AWD with Turf Mode 1000 lb./453.6 kg box, 1500 lb./680.4 kg total payload One ton/907.2 kg towing Removable under-seat storage New ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features Adjustable Dual A-Arm Front Suspension Exclusive Independent Rear Self Leveling Suspension with Nivomat shocks Variable assist power steering 9.63”/24.5 cm front travel, 9”/22.9 cm rear travel 12”/30.5 cm Ground Clearance Seating for three Work-enabling ergonomics including tilt steering, easier steering effort and seat back angle Available Lift & Carry with 500 lb capacity. Available in Sage Green RANGER 800 XP - Xtreme off-road performance New 800cc EFI engine provides 15 percent more horsepower and 53 mph/85.3 km top speed. Hardest Working Features 46 HP, 800 EFI Engine 53 MPH/85.3 km top speed Full instrumentation On Demand AWD with Turf Mode 1000 lb./453.6 kg box, 1500 lb./680.4 kg total payload One ton//907.2 kg towing Industry-leading storage – 140 percent increase Removable under-seat storage New ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features Adjustable Dual A-Arm Front Suspension Independent Rear Suspension 9.6 in/24.5 cm front travel, 9 in/22.9 cm rear travel 12 in/30.5 cm Ground Clearance Seating for three Work-enabling ergonomics including tilt steering, easier steering effort and seat back angle Available in Sage Green, Solar Red and Mossy Oak Break Up Limited Edition models include Pearl White, Navy/Sandstone and Browning Edition RANGER 800 6x6 - Unmatched cargo capacity and traction Updated styling, upgraded ergonomics and Dual A-arm front, middle and rear suspension with new 800cc EFI engine. Hardest Working Features 40 HP, 800 EFI Engine 46 MPH/74 km top speed Full instrumentation On Demand AWD 2000 lb./907.2 kg payload, 1250 lb./567 kg cargo capacity, 250 lb/113.4 job box One ton/907.2 kg towing Heavy duty front end protection, inset lights and the most protection for critical components. Removable under-seat storage New ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features Adjustable Dual A-Arm Front Suspension, middle and rear suspension with motion ratio adjustability Exclusive On-Demand, true six-wheel drive 9.6 in/24.5 cm front travel, 9 in/22.9 cm middle and rear travel 12 in/30.5 cm Ground Clearance Seating for three Work-enabling ergonomics including tilt steering, easier steering effort and seat back angle Available in Sage Green RANGER 500 H.O. - No. 1 choice for power and comfort New 500 H.O. EFI engine provides13 percent more power and 47 mph/75.6 km top speed. Hardest Working Features 30 HP, 500 EFI Engine 47 MPH/75.6 km top speed Lock & Ride Cargo System On Demand AWD with Turf Mode 1000 lb./453.6 kg box,1500 lb./680.4 kg total payload 1500 lb./ 680.4 kg towing Industry-leading storage – 140 percent increase ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features Adjustable Dual A-Arm Front Suspension Independent Rear Suspension 9.63 in/24.5 cm front travel, 9 in/22.9 cm rear travel 12 in/30.5 cm Ground Clearance Seating for three New, improved ergonomics including tilt steering, easier steering effort and seat back angle Available in Solar Red and Sage Green RANGER EV - Clean and Quiet Operation The first Polaris electric vehicle offers a 30 horsepower electric motor with two-hours of riding time and a 35-45 mile range. The vehicle includes a range leader with three modes, High, Low or Max, for different riding situations, 650 amp controller, AC induction motor for low maintenance/high performance and charges using a standard 110 outlet. Hardest Working Features 30 HP electric engine 25 MPH/40.2 km top speed On Demand AWD with Turf Mode 500 lb./22.68 kg box,1000 lb./453.6 kg total payload 1250 lb./ 567 kg towing Heavy duty front end protection with inset lights and the most protection for critical components. High-pressure 20 psi, 25in/63.5 cm tires ROPS Certified Cab Lock & Ride Cargo System Quick Charge Kit available through PURE Polaris Smoothest Riding Features MacPherson front suspension with Independent Rear Suspension 8 in/20.3 cm front travel, 9”/22.9 cm rear travel 10 in/25.4 cm ground clearance Seating for two Available in Boardwalk Blue and Mossy Oak New Break Up RANGER 400 - High Value 4x4 New value-priced RANGER 400 is a two-passenger, carbureted unit that shares many features from its full-sized counterparts: On-Demand True All-Wheel Drive with Turf Mode, Independent Rear Suspension, heavy-duty front end protection, high ground clearance, the longest suspension travel and the highest horsepower in its class. All of these features at the value price of $7,999. Hardest Working Features 29 HP, 450cc high output, carbureted engine 40 MPH/64.4 km top speed Lock & Ride Cargo System On Demand AWD with Turf Mode 500 lb./22.68 kg box,1000 lb./453.6 kg total payload 1250 lb./ 567 kg towing Heavy duty front end protection with inset lights and the most protection for critical components. ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features MacPherson front suspension with Independent Rear Suspension 8 in/20.3 cm front travel, 9”/22.9 cm rear travel 10 in/25.4 cm ground clearance RANGER 800 CREW - Hardest Working, Smoothest Riding Multi-Passenger Utility Vehicle Updated styling and ergonomics, new Dual A-arm front suspension and 800cc EFI engine Hardest Working Features 40 HP, 800 EFI Engine 46 MPH/74 km top speed Full instrumentation On Demand AWD 1750 lb./793.8 kg payload, 1000 lb./454 kg cargo capacity, one ton/907.2 kg towing Heavy duty front end protection, inset lights and the most protection for critical components. Front under-seat storage and rear side storage New ROPS Certified Cab Lock & Ride Cargo System Smoothest Riding Features Adjustable Dual A-Arm Front Suspension On-Demand, true all-wheel drive 9.6 in/24.5 cm front travel, 9 in/22.9 cm rear travel 12 in/30.5 cm Ground Clearance Seating for six Work-enabling ergonomics including tilt steering, easier steering effort and seat back angle 2 in/5.1 cm more leg room for rear passengers Available in Sage Green, Solar Red and Mossy Oak Break-Up Sandstone Metallic Limited-Edition model RANGER RZR - Razor Sharp Performance New 60 mph/96.6 km top speed, 52 horsepower and ROPS Certified Cab Only trail capable side-by-side at 50 inches wide with on-demand, true AWD Lowest center of gravity in its class for ground-hugging performance 800 Polaris EFI engine Lightest side-by-side at 945 lbs. Independent rear suspension All the utility you need with 300 lb. Lock & Ride cargo bed, 1,500 lb. towing New ROPS Certified Cab Available in Green and Red Limited Edition models include Tequila Gold and Turbo Silver RANGER RZR S - Razor Sharp Sport Performance ROPS Certified Cab 800 Polaris H.O. EFI engine Pure sport machine at 60 inches wide with 12 inches of long-travel suspension and 12.5 inches of ground clearance Chrome-Moly upper front A-arms for precision and strength Adjustable Fox® performance shocks with Podium reservoirs Lowest center of gravity in its class for ground-hugging performance Independent rear suspension On-demand, true AWD Fender flairs and extended rear cab frame supports for sportier look 26 inch Maxxis Big-Horn tires with 12 inch, black powder coated rims New ROPS Certified Cab Available in Pearl White with Black Rally Stripe Orange Madness Limited Edition model

For Sale New ATV's Polaris and Can-Am For Sale !!! Interested buyer should mail us direct for inquiry !!! Email: [email protected] OR [email protected] Skype: john.anders01 2015 Polaris RZR 1000 EPS Desert Edition 2015 Polaris RZR xp 1000 EPS Highlifter 2014 Polaris RZR xp 1000 EPS 4x4 Side By Side 2014 Polaris 850 XP Sportsman 2014 Can-Am Maverick 1000r X mr DPS 2014 Can-Am Outlander MAX 800R EFI LTD !!! Interested buyer should mail us direct for inquiry !!! Email: [email protected] OR [email protected] Skype: john.anders01

Just bought this for 1200 and it back fires when u really give it gas or rev it up n nuetral....can smell gas like its getting to much....would this cause this to back fire? what could it b

It worked intermittenly the last couple times I had it out. Now the switch will not work at all nor the 4 wheel drive. I got the hood off exposing the wires. I checked all connections. The wiring diagram shows the power is coming from the hub safty switch and going to the front AWD hubs and then to the AWD switch. I have no power to the switch. (After 96 & 97 Polaris did away with the hub safty switch.) Any help will be appreciated.

the start button quit working so i intalled new one, still nothing, it will not try and start at all like its not getting and power to the button so i thot its the cylinoid (which sits next to the battery which is above the left back tire) I put brand new one on still nothing...when i jump the cylinoid with a piece of copper wire it starts right up.... is there a fuse or something that leads to the starter button that could be blown? I took the seat off and tracked the wire from the cylinoid to the starter button and i noticed the wire goes into something that is wrapped in some kind of black rubber plastic looking square shaped thing... the wire goes in one side and out the other? what is inside that black rubber thing? a fuse? could that be the problem? i dont want to cut it open if i dont need to..... all help is needed thanks....

Need a polaris manual for a 1994 2 stroke 2/4x4 quad free. can you please post a link I can click on Thank you. Roxanne

Trying to change front wheel bearings. I removed the cotter pin and castle nut. Hub won't budge. Is there an additional retaining clip? Seems to be one of those push on type that barbs on the thread of the spindle. How do I remove it?

I am having an issue where it sounds like the gears are slipping if I hit the throttle really hard and also after letting off when the engine brake is applied. Also, the drive train that goes to the front also rides again the gear shift box. I will attach pictures and a video here shortly. Thanks in advance! [ame] [/ame]https://postimg.org/image/cdlu6fza9/

Looking for a download of a manual

Hi All, This is my first ATV and I'm picking it apart to learn about it. I noticed this tube hanging and can't figure out what it is. Can someone ID it for me and tell me where it plugs on to? It's a 2000 Xpedition 425. (Blue arrow points to the one I'm talking about.) I'm also looking for some real basic parts diagrams so I can learn more about this thing. If someone knows of anything similar to what I've posted for a Jeep feel free to point me in the right direction. Thanks!

I have a 97" polaris sportsman 500 and the 4 wheel drive wont work, it just didnt work one day. I dont know when or why it went out. It has a 4 wheel drive button on the handle bars and it is on and i have turned it on and off but no go............ any thoughts or ideas, please help. I need it for sat. i will never get out on this small lake for ice fishing with out my wheeler, thanks in advance jamie.

Thank you for your help, just got quad for my daughter n needs a little work [email protected] It's actually a 2002 , just found serial number. Thanks for any help that you can !

My 1995, 425 magnum has a " whinning " sound when accelerating. Does not make the noise at idle or when reving the engine. Only when its moving. Is this normal ?