Model:
Sportsman / Xplorer / Worker
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Vehicle Type:
All-Terrain Vehicle (ATV)
Chassis Codes:
Not specified, but models typically identified by year and sub-model designation
Engine Codes:
Various, primarily 500cc and 400cc variants, specific codes not detailed in product info
Positioning:
High-performance utility ATVs, targeted at recreational riders and those needing robust off-road capability.
Competitors:
Honda Foreman/Rubicon, Yamaha Kodiak/Grizzly, Suzuki King Quad, Can-Am Outlander (though Outlander entered later).
Features:
Powerful 500cc engine (later 400cc variants), independent suspension (on many models), robust chassis, suitable for a wide range of off-road tasks and recreation.
Value:
Provides comprehensive, dealership-level repair and maintenance information for a wide range of popular Polaris ATV models from the late 90s and early 2000s, enabling owners to perform complex repairs and proactive maintenance.
Primary Coverage:
1996-2003 Polaris Sportsman 500, Xplorer 500, Worker 500, Sportsman 400, and special editions
Specific Models Covered:
Sportsman 500 (1996-2003), Xplorer 500 (1997), Worker 500 (1998-2002), Sportsman 500 RSE (1999-2002), Sportsman 500 DUSE (2001-2003), Sportsman 500 H.O. (2001-2003), Sportsman 400 (2001-2003), Worker 400 (2002), Sportsman 400 ASEI (2002), Sportsman 400 DUSE (2002), Sportsman 500 H.O. Desert (2002), Sportsman 500 H.O. Freedom (2002), Sportsman Ducks Unlimited Special Edition (2003), Sportsman Remington Special Edition (2003)
Estimated Page Count:
Likely extensive, typical for dealer-level service manuals covering multiple years; exact count not provided.
Type:
Dealer Service/Repair Manual
Powertrain:
Engine top end, engine lower end, fuel system, cooling systems, clutch/drive belt system, transmission, final drive system
Chassis And Body:
Front suspension and steering, rear suspension, brakes, body
Electrical:
Electrical system, wiring diagrams
Specific Engine Components:
Cylinder head, valves, piston, crankshaft, camshaft, oil pump, starter motor, ignition system components.
Specific Drive Components:
Clutch components (primary, secondary), drive belt, gearcases, differentials, drive shafts, U-joints.
Maintenance:
Lubrication, maintenance, tune-up, service information (2001-2003), general maintenance procedures
Repair And Rebuild:
Engine repair (top and lower end), fuel system repair, cooling system repair, clutch and drive belt service, transmission repair, final drive service, suspension and steering component repair, brake system repair, body panel repair/removal
Troubleshooting:
Comprehensive troubleshooting guides for various systems
Special Tools:
Details necessary special tools for specific repair procedures.
Torque Specifications:
Provides torque specifications for all critical fasteners.
Depth:
Dealership level, including detailed step-by-step instructions, exploded views, and schematics; suitable for professional mechanics and advanced DIYers.
Diagnostics:
Includes troubleshooting flowcharts and diagnostic procedures for electrical and mechanical systems.
Compatibility:
All Versions of Windows & Mac
Required Software:
Adobe PDF Reader & WinZip
Quality Description:
Likely high-quality scans or digital reproduction of original dealer manuals, featuring clear pictures, exploded view illustrations, and schematics.
Binding:
Digital (PDF download), not a physical binding.
Paper Type:
Digital, no physical paper type.
Engine Type:
4-stroke, liquid-cooled, SOHC
Displacement:
Approximately 499cc (500 models) and 375cc (400 models)
Bore X Stroke:
Specifics vary by model, e.g., 93mm x 73.3mm for many 500cc models.
Compression Ratio:
Typically around 10.0:1 or 10.2:1 for 500cc models.
Horsepower:
Estimated 25-30+ HP depending on specific model and tuning.
Torque:
Specific figures vary, but designed for strong low-end and mid-range torque for off-road use.
Carburetor:
Mikuni BSR42 (typical for 500cc models). Specific jetting and tuning is a common manual coverage point.
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Cooling Method:
Liquid-cooled
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse.
Optional Transmissions:
None specified for these models; CVT was standard.
Clutch Type:
Automatic centrifugal clutch and drive clutch/driven clutch system with a drive belt.
Drive System:
Shaft drive to rear differential; front drive system typically on-demand AWD (All-Wheel Drive) or selectable 2WD/4WD.
Length:
Varies by model year, generally around 80-85 inches.
Width:
Varies by model year, generally around 45-48 inches.
Height:
Varies by model year, generally around 45-50 inches.
Dry Weight:
Typically in the range of 600-650 lbs.
Towing Capacity:
Often rated around 650-1500 lbs depending on model and specific year.
Cargo Capacity:
Front and rear racks, with capacity typically around 50-100 lbs front, 100-200 lbs rear.
Safety Ratings:
ATVs are not typically subject to standardized crash test ratings like passenger vehicles. Safety is dependent on operator skill and adherence to operational guidelines.
Braking System:
Hydraulic disc brakes on all wheels (typically dual front, single rear).
Drive System:
On-demand AWD provides enhanced traction in challenging terrain.
Operator Controls:
Handlebar steering, throttle lever, brake levers, gear selector.
Oil Change Engine:
Typically every 100 hours or 6 months, whichever comes first. Manual will specify exact intervals.
Filter Change Air:
Inspect frequently, clean/replace based on operating conditions (e.g., every 50-100 hours).
Belt Drive Inspection:
Inspect drive belt for wear, cracks, and proper tension at regular intervals (e.g., every 50-100 hours or annually).
Spark Plug Replacement:
Typically every 100-200 hours or annually. Specific gap is crucial.
Engine Oil Type:
Polaris 2W-50 Synthetic or equivalent API SG, JASO MA certified. Check manual for exact viscosity based on temperature range.
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water. Specific Polaris part numbers or equivalents are important.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type:
Polaris Synthetic Gearcase Lubricant or SAE 75W-90 (API GL-4) gear oil for front and rear differentials.
Common Problems:
CVT belt wear/failure, carburetor issues (jetting, clogging), starter solenoid problems, radiator leaks/fan failure, front differential seal leaks, suspension component wear.
Maintenance Tips:
Regularly inspect and clean the air filter, check CVT belt condition, maintain proper tire pressure, keep cooling system clean, and follow all lubrication schedules.
Brand Focus:
Polaris Industries has a long history in powersports, including snowmobiles and ATVs, known for innovation and performance.
Evolution Sportsman:
The Sportsman line, starting with the 500, became a flagship model for Polaris, known for its comfort, utility, and capable 4x4 system. The Xplorer was often a more sport-oriented variant, while Worker focused on utility. The 'HO' designation signifies 'High Output'.
Manufacturing Location:
Primarily USA (e.g., Roseau, Minnesota).
