Target User:
Polaris Sportsman Xplorer 400/500 4x4 owners and independent repair shops seeking in-depth technical guidance.
Value Proposition:
Provides year-specific, model-specific, and in-depth technical repair and maintenance information, surpassing generic manuals often found in the market.
Delivery Method:
Instant Download via email link, Fast, Easy & Secure transaction.
Payment Options:
Credit Card or PayPal
Coverage Specificity:
Highly specific to 1996-2003 Polaris Sportsman Xplorer 400 and 500 4x4 models.
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Estimated Page Count:
Extensive, likely 500+ pages based on depth of coverage
Type:
Workshop Service Repair Manual
Format:
PDF (Portable Document Format)
Engine:
Complete engine overhaul, rebuilding, diagnostics, lubrication, cooling system, fuel system (carburetor/EFI depending on model variant), ignition system, exhaust system, starting system.
Transmission Drivetrain:
Sub-transmission, main transmission, clutch system (primary and secondary), gearshift linkage, drive shafts, differentials (front and rear if applicable), 4x4 engagement system, wheel hubs.
Suspension Steering:
Front wheel and suspension (including A-arms, shocks, steering knuckles), rear wheel and suspension (including swingarm, shocks), steering system (handlebars, tie rods, steering shaft).
Brakes:
Hydraulic brake system (master cylinders, calipers, brake lines, brake pads/shoes), parking brake system, bleeding procedures.
Electrical:
Battery, charging system (alternator/stator, regulator/rectifier), ignition system, lighting system, starter motor, switches, wiring diagrams, troubleshooting electrical faults.
Chassis Body:
Frame inspection, body panel removal/installation, seat, racks, fenders.
Maintenance:
Regular service intervals, oil changes, filter replacements, lubrication points, tire pressure, belt inspection/tensioning, spark plug replacement, brake adjustments.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical diagnostic flowcharts.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly (e.g., engine rebuild, transmission overhaul, suspension component replacement, brake caliper rebuilding).
Inspection Adjustment:
Pre-ride checks, component inspection guidelines, linkage adjustments, cable adjustments, valve clearance checks and adjustments.
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics for all vehicle systems.
Depth:
Comprehensive workshop level. Covers everything from basic maintenance to full engine and transmission rebuilds, electrical diagnostics, and system component overhauls.
Engine Type:
Likely single-cylinder, 4-stroke (specific displacement varies between 400 and 500 models).
Displacement 400:
Approximately 375-399cc (actual specifications would be detailed in the manual).
Displacement 500:
Approximately 499-500cc (actual specifications would be detailed in the manual).
Horsepower Range:
Estimated 25-35 HP (varies by model year and engine size, specific figures in manual).
Torque Range:
Estimated 25-35 lb-ft (varies by model year and engine size, specific figures in manual).
Fuel Delivery:
Carbureted (likely Mikuni or Keihin) or early Electronic Fuel Injection (EFI) depending on specific sub-model and year. Manual covers diagnosis and repair of both.
Oil Type Recommendation:
Synthetic or semi-synthetic motorcycle/ATV engine oil, SAE 10W-40 or 20W-50 typically. Specific API service classification and capacity in manual.
Cooling Method:
Liquid-cooled.
Type:
Automatic Continuously Variable Transmission (CVT) with high/low range and reverse.
Gearbox Options:
N/A - CVT is standard.
Drive Modes:
2WD/4WD selectable, typically with automatic front differential engagement (e.g., Polaris Auto-Lock).
Cvt Belt Fluid Type:
Typically a specialized CVT fluid or the specified engine oil for belt lubrication and cooling. Refer to manual for precise specification.
Hi Low Range Ratios:
Specific ratios for High, Low, and Reverse gear ranges are detailed within the manual.
Overall Length:
Approx. 82-84 inches (2083-2134 mm) (varies slightly by model year).
Overall Width:
Approx. 46-48 inches (1168-1219 mm) (varies slightly by model year).
Overall Height:
Approx. 47-50 inches (1194-1270 mm) (varies slightly by model year).
Dry Weight:
Approx. 600-650 lbs (272-295 kg) (varies by model year and equipment).
Ground Clearance:
Approx. 8-10 inches (203-254 mm) (varies by model year).
Rack Capacity Front:
Typically around 100 lbs (45 kg).
Rack Capacity Rear:
Typically around 200 lbs (90 kg).
Atv Safety Standards:
Adheres to ANSI/SVIA standards for ATVs. Manual provides specific safety warnings and operating instructions.
Braking System:
Hydraulic disc brakes front and rear. Manual details maintenance and repair for optimal performance.
4Wd System:
Polaris's proven 4x4 system for enhanced traction. Manual covers engagement and maintenance.
Handlebars Grips:
Ergonomic handlebars with comfortable grips, designed for control and reduced fatigue. Manual covers inspection and replacement.
Lighting:
Headlights, tail light, and brake light for visibility. Manual details electrical system and bulb replacement.
Display Features:
Basic digital gauge cluster typically includes speedometer, odometer, trip meter, engine hour meter, and 4WD indicator. Manual details gauge function.
Traction Control:
Limited; primarily relies on the 4x4 system and tire tread for traction.
Usb Charging:
Not standard on models from this era. Accessories might be available.
Oil Change Interval:
Typically every 50-100 hours or annually, whichever comes first. Specific interval in manual.
Air Filter Cleaning:
Frequent cleaning (e.g., every 25-50 hours), replacement as needed. Manual provides specific instructions.
Spark Plug Replacement:
Recommended every 100-200 hours or annually. Manual specifies plug type and gap.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Specific type and capacity in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies exact type and bleeding procedure.
Gearcase Oil Capacity:
Front and rear gearcase oil capacity specified in manual. Typically 80W-90 or 85W-140 gear oil.
Cvtlifetime:
CVT belt wear is a common maintenance item; proper belt tension and condition are critical for performance. Manual covers inspection and replacement.
Charging System:
Stator or regulator/rectifier failures can occur over time. Manual provides diagnostic steps for the charging system.
Carburetor Issues:
Carburetor clogging or maladjustment can affect performance. Manual details cleaning, adjustment, and rebuilding procedures.
Polariss Atv Legacy:
Polaris has been a pioneer in the ATV industry since the 1980s, known for innovation and rugged capability. The Sportsman line is a cornerstone of their off-road offerings.
Sportsman Series:
The Sportsman series evolved from earlier Polaris models, focusing on comfort, independent suspension, and 4x4 capability. The Xplorer sub-line often represented more rugged, utility-focused variants.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Inc.
