Positioning:
The Polaris Sportsman Xplorer series represented Polaris's commitment to versatile, rugged all-terrain vehicles suitable for utility work and recreational trail riding during the late 1990s and early 2000s.
Competitors:
Competed against similar models from brands like Yamaha (Kodiak, Wolverine), Suzuki (King Quad), and Honda (FourTrax Foreman).
Features:
Independent front suspension, shaft-driven AWD system, powerful Polaris engines, comfortable seating, robust utility racks.
Engine:
Complete engine overhaul, top-end and bottom-end assembly, valve adjustments, carburetor tuning, ignition system, cooling system (if applicable).
Transmission:
ATV automatic transmission service, belt inspection and replacement, clutch adjustments, gear case maintenance.
Drivetrain:
All-wheel drive (AWD) system operation, front and rear differential service, driveshaft inspection, CV joint maintenance.
Suspension:
Front and rear suspension component inspection, shock absorber replacement, A-arm service, bushing replacement.
Brakes:
Hydraulic brake system diagnosis, brake pad replacement, rotor inspection, bleeding procedures, parking brake adjustment.
Electrical:
Wiring diagrams, starter system, charging system (stator, regulator/rectifier), battery maintenance, lighting system, ignition switch, fuses, relays.
Fuel:
Fuel tank inspection, fuel lines, fuel pump operation, fuel filter replacement, carburetor cleaning and rebuilding.
Bodywork And Chassis:
Frame inspection, plastic body panel removal and installation, seat maintenance, handlebars, footpegs.
Cooling System:
Radiator, fan, coolant hoses, thermostat replacement, flushing procedures (for liquid-cooled models).
Exhaust System:
Muffler inspection, exhaust pipe sealing, heat shield checks.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, spark plug replacement.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting guides, electrical troubleshooting procedures.
Repair:
Step-by-step repair procedures for all major components and systems, disassembly and reassembly instructions.
Diagnostics:
Testing procedures for electrical components, engine performance diagnostics, fuel system testing.
Depth:
Comprehensive coverage suitable for DIY mechanics and professional technicians, including detailed torque specifications, clearances, and diagnostic data.
Engine Type:
4-stroke, Liquid-Cooled, SOHC
Displacement:
Approximately 375cc to 400cc (specific variant dependent)
Engine Type:
4-stroke, Liquid-Cooled, SOHC
Displacement:
Approximately 499cc to 500cc (specific variant dependent)
Horsepower:
Estimated 25-30 HP (varies by specific model year and tuning)
Torque:
Estimated 28-32 ft-lbs (varies by specific model year and tuning)
Carburetor:
Mikuni VM34 or similar (specific model dependent), or potentially Keihin CVK.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled with radiator and fan
Engine Oil Capacity:
Approx. 2.2 - 2.5 Liters (check manual for exact spec)
Length:
Approx. 83-85 inches (varies by year)
Width:
Approx. 46-48 inches (varies by year)
Height:
Approx. 47-49 inches (varies by year)
Wheelbase:
Approx. 50-51 inches (varies by year)
Ground Clearance:
Approx. 8-10 inches (varies by year)
Dry Weight:
Approx. 550-600 lbs (varies by year)
Front Rack Capacity:
Approx. 100 lbs
Rear Rack Capacity:
Approx. 200 lbs
Fuel Tank Capacity:
Approx. 3.2 - 3.7 Gallons (varies by year)
Ratings:
ATVs are not typically subject to the same crash ratings as passenger vehicles. Safety relies on operator skill and adherence to safe riding practices.
Braking System:
Hydraulic disc brakes front and rear.
Throttle Limiter:
Often featured on models for younger riders or beginners, though less common on utility models like the Xplorer.
Lighting:
Headlights, taillight, and brake light for visibility.
Operator Controls:
Handlebar steering, ergonomic controls for throttle, brakes, and gear selection.
Infotainment Features:
Basic instrumentation typical for this era: speedometer, odometer, hour meter, fuel gauge, warning lights. No complex infotainment systems.
Driver Assistance Features:
None typical for this generation of ATVs.
Connectivity Features:
No electronic connectivity features.
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first (consult manual for exact intervals).
Air Filter Cleaning:
Check every 20-40 hours of operation, clean as needed, replace if damaged.
Spark Plug Replacement:
Recommend replacement every 1-2 years or per mileage/hour recommendations.
Belt Inspection Cv Drive:
Inspect drive belt for wear and damage at least annually or every 100 hours.
Engine Oil Type 400 500:
SAE 20W-50 API SG or higher motorcycle-specific oil is generally recommended. Verify with manual for exact specification.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Check manual for specific Polaris coolant or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type:
Hypoid gear oil, SAE 80W-90 API GL-5 (check manual for specific Polaris brand or equivalent).
Common Wear Items:
CV boots, brake pads, drive belts, wheel bearings, ball joints, tie rod ends, and carburetor jets are common wear items requiring regular inspection and replacement.
Electrical Gremlins:
Intermittent electrical issues, especially related to the CDI unit, stator, or charging system, can occur with age and exposure to elements. Refer to electrical troubleshooting sections.
Carburetor Fouling:
Carburetors can become fouled from stale fuel or debris, leading to rough running or starting issues. Regular cleaning and proper fuel storage are key.
Polarishistory:
Polaris Industries, founded in 1954, is a major American manufacturer of off-road vehicles, including snowmobiles, ATVs, and UTVs. They have a long history of innovation in the powersports industry.
Sportsman Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, independent suspension, and utility capabilities. The Xplorer designation often indicated a more premium or specialized version within the Sportsman family, focusing on extended-range or more demanding terrain.
Production Period:
The Polaris Sportsman Xplorer 400/500 models covered by this manual were produced from 1996 through the 2003 model year, representing a significant period of ATV development.
