See our and for details. Replace all O-rings, seals, and worn components. Keep Your All-Terrain Vehicle Running Smoothly. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. Loosen the hub retaining nut. See Battery Installation on page 10.
Re- fer to bushing replacement in this chapter. How to change spark plug on a 2007 polaris sportsman 500 free repair manual for a 2003 sportsman polaris 500 free manual book on atv sportsman 500 polaris 2000 fix it and repair download polaris 500 sportsman repair manuals download 99 polaris 500 sportsman repair manuals diagram electric polaris sportsman 500 change the brakes on a 2006 polaris sportsman 500 carbuert adjustment for 500cc polaris 4wheeler 2003 can a 500 engine fit into a 300 polaris sportsman 99 polaris sportsman 500 manual 97 polaris sportsman 500 4x4 blows black smoke. Check all connections for leaks and repair if necessary. Check valve face for runout, pitting, and burnt spots. Only a qualified technician should replace worn or damaged steering parts. As the fuel fills the float cham- ber, the float 1 rises and forces the inlet needle against the seat, shutting off the orifice in the seat. How to replace the front guards of a polaris sportsman 500 4x4 1998 02 polaris sportsman 500 4x4 free service manual 1999 polaris sportsman 500 valve adjustment 2000 polaris sportsman 500 repair manual pdf 2001 polaris sportsman 500 service manual pdf 2003 polaris sportsman 500 wiring diagram 2004 sportsman 4 wheeler 500 wiring diagram free 2005 polaris sportsman 500 service manual pdf 2006 polaris sportsman 500 troy lee edition repair manual.
Remove front output ring gear. Remove left rear drive shaft see page 7. Cover every aspect of repair. Inspect ramp buttons in the moveable sheave and replace if worn. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record.
Remove cam chain drive sprocket B and Woodruff key from crankshaft. S Tighten shift linkage rod end jam nuts properly after adjustment. If any of the above conditions exist, the valve seat must be reconditioned. Attach the puller legs to the main puller body. Be sure hole is clear 9.
Install main adapter Item 8 on puller. Install caliper on hub strut, and torque mounting bolts. Align bottom of carrier housing and lower control arm. To calculate proper end play, subtract total shim thickness from end play measured in step 8. Repeat steps 1-3 to install bearing caps on outer yoke.
Remove rear hub and bearing carrier. Place rope in notch on outer edge of reel. Assemble rocker arms, rocker shaft, and shaft supports. Lift bearing carrier into place and install bolt to upper control arm. It contains information on ever aspect of repair.
Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. If the valve seat is cracked the cylinder head must be replaced. Remove cotter pin and nut from lower A-arm ball joint. Remove caliper mounting bolts and lift caliper off of disc. Install wheels and torque wheel nuts. Replace any parts found to be worn or damaged. Remove camshaft sprocket inspection cover.
Carefully lift and support the front end of the machine as shown with the jack stands under the front end of the foot rests. Remove pump shaft bearing A and thrust washer B from pump shaft. Rear Wheel Nuts 20 Ft. Grasp rear of side panel near rear Step 1. Slide the shift dog over the spline and the low range shift shaft. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Visually inspect each cam lobe for wear, chafing or damage.