Product Type:
Workshop Service and Repair Manual
Product Name:
1996-2003 Polaris Sportsman / Xplorer / Worker 400 & 500 ATVs Service Repair Manual
Product Format:
Downloadable PDF
Covered Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Target Audience:
Polaris ATV owners, DIY enthusiasts, mechanics, restoration specialists
Value Proposition:
Provides dealership-level repair and maintenance information, saving owners significant costs compared to professional servicing. Instant download offers immediate access, avoiding shipping delays and costs.
Manual Features:
Comprehensive, highly detailed, printable pages, instant download, covers a wide range of models and years, includes diagrams and torque specs.
Vehicle Models Covered:
Polaris Sportsman 400, Polaris Sportsman 500, Polaris Xplorer 500, Polaris Worker 400, Polaris Worker 500, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 500 Remington Special Edition, Worker 400 (International), Sportsman 400 ASEI, Sportsman 400 DUSE, Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom, Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400 Desert
Type:
Official Full Workshop Service and Repair Manual (FSM)
Compatibility:
All Versions of Windows & Mac
Major Systems:
General Information, Troubleshooting, Lubrication, Maintenance, Tune-Up, Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, Bodywork, Wiring Diagrams, Carburetion, Final Drive, Drive Train
Key Procedures:
Complete tear down and rebuild, maintenance schedules, repair procedures, troubleshooting guides, engine overhaul, clutch adjustment, transmission service, brake maintenance, electrical system diagnostics, suspension setup, steering system service, fuel system cleaning and adjustment, cooling system maintenance, lubrication procedures, installation of parts, performance tuning
Depth Of Information:
Highly detailed, covering everything a dealer technician would use. Includes pictures, part diagrams, torque specifications, error codes, and advanced diagnostics.
Engine Types:
400cc and 500cc engines, specific variants like H.O. (High Output)
Engine Details:
Covers engine top-end (cylinder head, valves, piston, connecting rod) and lower-end (crankshaft, crankcase, primary reduction gear) for both 400 and 500cc displacements. Includes information on compression ratio, bore, stroke, and potential performance tuning.
Fuel System Components:
Fuel System, Carburetion, Carburetor (main jet, pilot jet, mixture screw, idle adjustment), Fuel Injection (EFI) for relevant models, fuel pump, intake manifold, fuel tank, fuel filter.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) is common across these models, though specific details on ratios and operation are covered.
Optional Transmissions:
N/A (CVT is standard)
Transmission Coverage:
Clutch/Drive Belt System (drive clutch, driven clutch, belt inspection and replacement), Transmission service, Final Drive, Front Drive System (driveshaft, differentials), Reverse gear operation.
Body Dimensions:
Covers body panels, fenders, plastics, seat, handlebars, and overall vehicle construction. Specific dimensional data (width, length) may be present within diagrams or specifications.
Weight Specifications:
Information on dry weight, wet weight, and carrying capacity is typically included in general information or specifications sections.
Safety Ratings:
N/A (ATV safety ratings are generally not standardized or published in the same way as passenger vehicles)
Active Safety Features:
Brake system (hydraulic, disc brakes), steering system, suspension performance.
Passive Safety Features:
Body construction, frame integrity, protective plastics.
Recommended Intervals:
Detailed maintenance schedules covering initial break-in service, regular checks (oil, filter, spark plug), and periodic major services are provided. Intervals are specified in hours or mileage/time.
Fluid Recommendations:
Engine oil type and viscosity (e.g., SAE 20W-50 for some models), coolant type and mixture, brake fluid type (DOT 3 or 4), transmission/gearbox oil specifications, and grease types for lubrication points are detailed.
Common Wear Items:
The manual would address common wear items like drive belts, suspension bushings, brake pads, wheel bearings, and potential issues related to carburetion or electrical components based on the model year.
Tune Up Procedures:
Procedures for spark plug inspection and gap setting, carburetor adjustment (idle speed, mixture), air filter cleaning/replacement, valve clearance checks and adjustments, and ignition timing checks are covered.
Brand History:
Polaris is a long-standing manufacturer of powersports vehicles, known for its innovation in ATVs and snowmobiles.
Model Line Evolution:
The Sportsman, Xplorer, and Worker lines represent Polaris's utility and sport ATV offerings during the late 1990s and early 2000s, with continuous updates and engine variations (e.g., introduction of H.O. models).
Production Period:
1996-2003 for the models covered in this specific manual.
