The Polaris Sportsman 335 and Sportsman 500 All-Terrain Vehicles (ATVs) represent robust engineering and reliable performance, built for a wide range of off-road applications. Introduced in the year 2000, these models are recognized for their independent suspension, comfortable ride, and utility-focused design, making them a versatile choice for work and recreation. A manufacturer with a rich history in powersports, has established the Sportsman line as a flagship series, emphasizing durability and capability in diverse terrains. This comprehensive factory service and repair workshop manual provides in-depth guidance for owners, professional mechanics, and technicians. It covers all essential aspects of maintenance, troubleshooting, and repair for your Polaris Sportsman ATV. Within its hundreds of pages, you will find detailed procedures for engine overhaul, drivetrain service, chassis system maintenance, and electrical system diagnostics, complemented by hundreds of photos and diagrams. The manual equips you with the knowledge for everything from routine oil changes and filter replacements to complex engine rebuilds and electrical troubleshooting, ensuring your vehicle remains in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2000 Vehicle Type: All-Terrain Vehicle (ATV) Product Type: Factory Service & Repair Workshop Manual Codes Manual Format: PDF Download 👋 Introduction Market Position Target User: Professional mechanics, ATV technicians, and experienced DIY enthusiasts. Competitive Analysis Manual Value Proposition: Offers the same detailed, factory-level information as professional workshop manuals, without ongoing costs or restrictions. Key Features Download Policy: Instant download, no expiry dates, no additional fees. Licensing: Lifetime usage rights on unlimited devices. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, and Troubleshooting Procedures Page Count Estimated Pages: Hundreds Manual Type Manual Classification: Factory Service Manual / Workshop Manual Language Primary Language: English Format Digital Compatibility: Compatible with Windows and MAC computers, tablets, and smartphones 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, tuning, carburetor service, cooling system, lubrication, valve adjustment, ignition system, starting system, fuel system. Drivetrain Systems: Transmission service (including gearcase, clutch, and drive system), final drive, driveshafts, CV joints. Chassis Systems: Suspension (front and rear), steering system, braking system (hydraulic and mechanical components), wheels, tires. Electrical Systems: Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery service, ignition switch, starter motor, instrumentation. Body And Frame: Body panel removal and installation, frame inspection, seat assembly, rack systems. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug service, air filter cleaning/replacement, brake fluid flush. Troubleshooting: Diagnostic procedures for common and uncommon issues, electrical system troubleshooting, engine performance problems, transmission faults. Repair: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major ATV systems. Rebuilds: Complete engine rebuild procedures, transmission overhauls, carburetor rebuilding. Installation: Instructions for installing genuine Polaris accessories or replacement parts. Technical Depth Depth Of Information: Professional-grade, with detailed step-by-step instructions, torque specifications, clearances, and diagnostic flowcharts. Diagrams And Photos: Hundreds of detailed photos and exploded diagrams illustrating disassembly, reassembly, and component identification. 📊 Manual Specifications File Format File Type: PDF Print Quality Printable Options: Full print capability for single pages or the entire manual. Binding Type Digital Access: Unlimited, lifelong access on multiple devices. Paper Type Digital Media: Downloadable digital file. ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled (typically for 500 model), Air-Cooled (typically for 335 model) Displacement Sportsman 335: Approximately 335cc Displacement Sportsman 500: 499cc Bore X Stroke Sportsman 500: 93.0 mm x 73.0 mm (typical) Compression Ratio Sportsman 500: 9.0:1 (typical) Performance Horsepower Sportsman 500: Approx. 26-28 HP (peak, dependent on tuning and specific configuration) Torque Sportsman 500: Approx. 28-30 lb-ft (peak, dependent on tuning and specific configuration) Fuel System Carburetor Sportsman 500: Mikuni BSR42 (typical) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 3.2 US gallons (approx. 12.1 liters) 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive System: Shaft Drive (2WD/4WD selectable on some models) Features Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) 📐 Dimensions Exterior Length: 82.0 in (approx. 208.3 cm) Width: 45.0 in (approx. 114.3 cm) Height: 47.0 in (approx. 119.4 cm) Weights Dry Weight Sportsman 500: 570 lbs (approx. 258.5 kg) Ground Clearance: 4.5 in (approx. 11.4 cm) Towing Capacity: 1500 lbs (approx. 680 kg) Rack Capacity Front: 90 lbs (approx. 40.8 kg) Rack Capacity Rear: 180 lbs (approx. 81.6 kg) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes (front and rear), mechanical rear brake actuator. Parking Brake: Integrated into the transmission/drivetrain or a separate caliper mechanism. Passive Features Lighting: Dual headlights, taillight/brake light. Operator Controls: Handlebar throttle, brake lever, gear selector. 💡 Technology Features Infotainment Instrumentation: Digital speedometer, odometer, trip meter, fuel gauge (on some models), indicator lights for 2WD/4WD, oil pressure, high beam. Driver Assistance Engine Braking: Standard feature of the PVT system, providing downhill braking assistance. Connectivity Diagnostic Ports: On-board diagnostics (OBD) capabilities for advanced troubleshooting accessible via specific connectors. 🔧...