Model:
Sportsman 400, Sportsman 500, Xplorer 500 4x4
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Vehicle Type:
All-Terrain Vehicle (ATV)
Target User:
Work, recreation, hunting, trail riding.
Competitors:
Yamaha Kodiak, Suzuki King Quad, Honda Foreman (during their respective production eras).
Atv Features:
4x4 capability, independent front suspension (IFS) on many models, robust utility chassis, Polaris Variable Transmission (PVT).
Manual Benefit:
Empowers owners and technicians with the authoritative information needed for proper maintenance, repair, and longevity of these durable ATVs.
Primary Coverage:
Complete Service, Repair, and Maintenance
Specific Models Covered:
Polaris Sportsman 400 4x4, Polaris Sportsman 500 4x4, Polaris Xplorer 500 4x4
Estimated Page Count:
Over 500 pages (typical for comprehensive factory service manuals)
Type:
Factory Service Manual
Description:
Official factory-level repair and maintenance documentation.
Format:
PDF (Instant Download)
Engine:
Detailed diagnostics, repair, overhaul, timing, cooling, lubrication, fuel delivery, ignition systems.
Transmission Drivetrain:
Automatic transmission operation, maintenance, repair (PVT - Polaris Variable Transmission), final drive, differentials, driveshafts, CV joints.
Suspension Steering:
Front and rear suspension systems (e.g., MacPherson struts, independent suspension), shock absorbers, steering components, tie rods, universal joints.
Brakes:
Hydraulic brake system inspection, maintenance, caliper and master cylinder repair, bleeding procedures, disc and pad replacement.
Electrical:
Wiring diagrams, battery system, starter, charging system (alternator/stator), lighting, ignition switch, fuses, relays, troubleshooting electrical faults.
Fuel System:
Carburetor operation, tuning, cleaning, fuel pump, fuel lines, fuel tank maintenance.
Body Frame:
Body panel removal and installation, frame inspection, seat removal, rack systems.
Cooling System:
Radiator, fan, hoses, coolant specifications and change intervals.
Wheels Tires:
Tire pressure recommendations, wheel torque specifications.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments.
Troubleshooting:
Diagnostic flowcharts, common problem identification and resolution strategies, electrical diagnostic procedures.
Repair:
Step-by-step instructions for component removal, overhaul, replacement, and reassembly for all major systems.
Rebuilds:
Engine and transmission component rebuild procedures, including specifications and tolerances.
Specifications Torques:
Torque specifications for all fasteners, engine clearances, bearing tolerances, and other critical measurements.
Depth:
Comprehensive: Covers everything from basic rider-level maintenance to in-depth engine and transmission overhauls.
Detail Level:
Factory-level detail with exploded views, diagrams, and clear instructions.
Engine Type 400:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder
Engine Type 500:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (often based on the same platform with displacement variations).
Displacement 400:
Approximately 375cc - 400cc (varies slightly by specific model year and sub-model)
Displacement 500:
Approximately 499cc - 500cc (varies slightly by specific model year and sub-model)
Horsepower Estimate 400:
Approx. 25-30 HP
Horsepower Estimate 500:
Approx. 30-35 HP
Torque Estimate 500:
Approx. 28-32 ft-lbs
Carburetor Type:
Mikuni (e.g., VM34SS or similar for 400, VM36SS or similar for 500)
Fuel Type:
Unleaded Gasoline (87 octane or higher)
Atv Classification:
Utility ATV (Not designed for passenger transport or highway use)
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight, brake light.
Ergonomics:
Handlebar grips, throttle control, brake levers designed for ATV operation.
Oil Change Engine:
Every 100 hours or 6 months (whichever comes first).
Air Filter Cleaning:
Inspect every 20-40 hours, clean or replace as needed.
Spark Plug Replacement:
Every 100 hours or 12 months.
Belt Inspection Pvt:
Inspect every 40 hours for wear and tension; replace as per manual recommendations (often around 1500-2000 hours or based on visual inspection).
Engine Oil Type:
SAE 5W-50 Synthetic (Polaris brand recommended, or equivalent meeting API SG/SH/SJ)
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (check dipstick)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Pvt Belt Wear:
CVT belt can wear prematurely if subjected to excessive slipping, heat, or improper tension.
Carburetor Cleaning:
Carburetors can become clogged with debris or varnish if fuel is left sitting for extended periods.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues.
Suspension Bushings:
Wear in suspension pivot bushings can lead to play and improper handling.
Starter Solenoid:
Solenoid failure can prevent engine cranking.
Polariscamv History:
Polaris is a long-standing American manufacturer of powersports vehicles, known for innovation in ATVs and snowmobiles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from earlier models with a focus on comfort, utility, and 4x4 capability.
Xplorer Line:
The Xplorer was often positioned as a more premium or performance-oriented utility ATV within the Polaris lineup during this era.
Manufacturing Location:
United States (Minnesota)
