Polaris ATV Magnum 500 4x4 User Manual

OWNER’S MANUAL SUPPLEMENT
2002 500 MAGNUM 4x4
PN 9917112

IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s manual at all

times.

Capacities

Body Style Gen IV

Gross Vehicle Weight 1 150

Fuel Capacity 3.2 U.S. Gallons

Transmission Oil 400 ml

Front Housing Gearcase Oil 150 ml

Rear Housing Gearcase Oil 150 ml

Engine OIl Capacity 2 Quarts

Front Rack (Maximum ­Capacity)

Rear Rack 180 Lbs.

Tongue Weight 35 Lbs.

Tow Hitch Standard

Tow Capacity 1225 Lbs.

Turn Radius 65〉

Ground Clearance 7.25〉

Height 47.5〉

Length 81〉

Seat Height 34〉

Dry Weight 647 Lbs.

Wheel Base 49.75〉

Width 46〉

90 Lbs.

Drive System

Drive System Type PVT

Shift Type Side Lever (Hi/Low-

R-N)

Gear Reduction - Low 7.50/1

Gear Reduction - Reverse 5.12/1

Gear Reduction - Foward 3.3/1

Front Drive (ratio) 3.7/1

Final Drive (ratio) 3.1/1

Center Drive (ratio) Not Applicable

Drive Chain Not Applicable

Front Tire 25 x 8-12 / 4psi

Rear Tire 25 x 11-12 / 3 psi

Suspension and Brakes

Front Susp. - Mac Strut 6.7〉

Rear Susp. - Progresseive
Rate Swing Arm

Shock Adjustment CAM

Front Brake Fixed disc, hydraulic

Rear Brake Hydraulic Floating

Auxiliary Brake Hydraulic Floating Cal-

Park Brake Hydraulic Lock/All

6.5〉

floating caliper

Caliper

iper

Wheel

Engine & Cooling

Engine Model Number EH-50PLE-08

Engine Type 4 Cycle, Single Cylinder

Lubrication Dry Sump

Bore x Stroke 92 x 75 mm

Displacement 498

Compression Ratio 10:2 Full Stroke

Engine Cooling Liquid

Alternator Output (watts) 250

Carburetion 1/BST34

Main Jet 157.5

Pilot Jet 40

Needle Jet Q-0

Pilot Screw 25/8Turns

Jet Needle 4HB40-2

Ignition CDI

Timing 30 @ 3500  1.5

Spark Plug Gap .7 mm/.028 in.

Spark Plug Type BKR5E

Exhaust USFS Approved

Features

Headlight (watts) 1 single beam/60 Grill -

2 single beam/27

Taillight (watts) 8.26

Brake Light (watts) 26.9

3-Point Hitch Accessory

Battery 12V 14 AH

DC Plug In - Rear Accessory

High Beam Indicator Standard

High Temp Indicator Standard

Windshield Accessory

Low Oil Light Not Applicable

Neutral Indicator Standard

Reverse Indicator Standard

Speedometer Standard

Tool Kit Standard

Electric Start Standard

Carburetor Jetting Clutching Chart

Alti-

tude

Meters

(Feet)

AMBIENT

TEMPERATURE

0-1800

(0-6000)

1800 & above

(6000 & above)

PN 9917112 Rev 01 3/01
E 2000 Polaris Sales Inc.

Printed in U.S.A.

Below +40 F

Below +5 C

+40 F&

Above

Altitude Shift

+5 C&

Above

162.5

157.5 Meters
(Feet)

155 150 1800 & above

(6000 & above)

*EBS Models require no spring/helix adjustment

0-1800

(0-6000)

Weight

10MH

5630513

10WH

5630710

Drive
Clutch
Spring

Blue/

Green

7041157

Blue/

Green

7041157

Driven-

Clutch
Spring

White/
Yellow

7041635

White/
Yellow

7041635

Helix

Spring

EBS*

5132751

EBS*

5132751