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This Official 1996-2000 Polaris Sportsman 335 500 ATV Factory Service Manual provides detailed service information, step-by-step repair.
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DOWNLOAD ATV Service Repair Manuals & Owner's Manuals By Brand. RELATED ATV SERVICE MANUAL SEARCHES: FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTINGExcessive exhaust noise. Deformed exhaust system.
Exhaust gas leaks. Poor performance. Clogged muffler. Broken exhaust system. Exhaust gas leaks. LUBRICATION SYSTEM TROUBLESHOOTINGOil level too low - high oil consumption.
Oil consumption. External oil leak. Worn piston rings or incorrect piston ring installation. Worn cylinder. Worn valve guide or stem seals.
Oil pump worn or damaged. Oil contamination. Oil or filter not changed often enough. Worn piston rings or incorrect piston ring installation. Worn valve guide or stem seals. FUEL SYSTEM TROUBLESHOOTINGEngine cranks but won’t start. No fuel in tank. No fuel to carburetor.
Clogged fuel strainer. Clogged fuel line. Clogged fuel tank breather tube.
Misadjusted fuel level. Too much fuel getting to the engine. Clogged air cleaner. Flooded carburetor. Intake air leak. Contaminated/deteriorated fuel.
Clogged jets. Clogged starting enrichment valve circuit. Improper starting enrichment valve operation. Improper throttle operation. No spark at plug (faulty ignition system)Lean mixture. Clogged fuel jets. Faulty float valve.
Float level too low. Restricted fuel line. Clogged carburetor air vent tube.
Restricted fuel tank breather tube. Intake air leak. Faulty vacuum piston. Faulty throttle valve. Rich mixture. Starting enrichment valve open (ON)Clogged air jets. Faulty float valve.
Float level too high. Dirty air cleaner. Worn jet needle or needle jet. Faulty vacuum piston. Engine stalls, hard to start, rough idling. Restricted fuel line.
Fuel mixture too lean/rich. Contaminated/deteriorated fuel. Clogged jets. Intake air leak. Misadjusted idle speed.
Misadjusted pilot screw. Misadjusted float level. Restricted fuel tank breather tube. Clogged air cleaner. Clogged slow circuit. Clogged starting enrichment valve circuit. Faulty ignition system Afterburn when engine braking is used.
Leanmixture in slow circuit. Faulty air cut- off valve.
Faulty ignition system. Backfiring or misfiring during acceleration. Lipps Funky Town Free Download. Leanmixture. Faulty ignition system. Poor performance (driveability) and poor fuel economy. Clogged fuel system.
Faulty ignition system. CYLINDER HEAD/VALVE TROUBLESHOOTINGEngine top- end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top- end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring. Compression too low, hard starting or poor performance at low speed.
Valves. Incorrect valve adjustment. Burned or bent valves. Incorrect valve timing. Broken valve spring. Uneven valve seating.
Valve stuck open. Cylinder head. Leaking or damaged cylinder head gasket. Warped or cracked cylinder head. Loose spark plug. Compression too high. Excessive carbon build- up on piston head orcombustion chamber.
Worn or damaged decompressor system. Excessive smoke. Worn valve stem or valve guide. Damaged stemseal. Cylinder/piston problem. Excessive noise. Incorrect valve clearance. Sticking valve or broken valve spring.
Excessive worn valve seat. Worn or damaged camshaft. Worn rocker arm and/or shaft.
Worn rocker arm follower or valve stem end. Worn or damaged push rod and/or cam follower. Worn cam chain. Worn or damaged cam chain tensioner. Worn cam sprocket teeth.
Cylinder/piston problem. Rough idle. Low cylinder compression. CYLINDER/PISTON TROUBLESHOOTINGCompression too low, hard starting or poor performance at low speed. Leaking cylinder head gasket. Worn, stuck or broken piston ring. Worn or damaged cylinder and piston. Bent connecting rod.
Compression too high, overheating or knocking. Excessive carbon built- up on piston head or combustion chamber. Excessive smoke. Worn cylinder, piston or piston rings. Improper installation of piston rings. Scored or scratched piston or cylinder wall. Abnormal noise. Worn piston pin or piston pin hole. Worn connecting rod small end.
Worn cylinder, piston or piston rings. CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTINGClutch slips when accelerating. Incorrect clutch adjustment.
Worn clutch discs. Weak clutch springs. Faulty clutch lifter. Improper oil viscosity or oil additive used. Clutch will not disengage.
Faulty clutch lifter. Warped clutch plates.
The vehicle creeps. Faulty centrifugal clutch. Clutch operating feels rough. Worn clutch outer and center grooves. Warped clutch plates. Loose clutch lock nut. Faulty clutch lifter.
Improper oil viscosity or oil level. Hard to shift. Incorrect clutch adjustment Worn or damaged gearshift cam and stopper arm. Faulty clutch lifter. Improper engine oil viscosity. Bent fork shaft and gearshift spindle or damaged shift forks and shift drum. Transmission jumps out of gear.
Broken shift drum stopper arm. Weak or broken shift linkage return springs. Worn or damaged gearshift cam. Bent fork shaft or worn shift forks and shift drum Worn gear dogs or slots.