🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400 / 500 / Xplorer 500

Product Type:

Service Repair Manual

Format:

PDF Download

Common Model Codes:

A03CH50AA (Sportsman 400), A03CH50AB (Sportsman 400), A04CH50AA (Sportsman 400), A05CH50AA (Sportsman 400), A06CH50AA (Sportsman 400), A03CH50BB (Sportsman 400), A03CH50CB (Sportsman 400), A04CH50BB (Sportsman 400), A05CH50BB (Sportsman 400), A06CH50BB (Sportsman 400), A03CB50AA (Sportsman 500), A04CB50AA (Sportsman 500), A05CB50AA (Sportsman 500), A06CB50AA (Sportsman 500), A07CB50AA (Sportsman 500), A08CB50AA (Sportsman 500), A09CB50AA (Sportsman 500), A10CB50AA (Sportsman 500), A11CB50AA (Sportsman 500), A12CB50AA (Sportsman 500), A03CH50FB (Sportsman 500), A04CH50FB (Sportsman 500), A05CH50FB (Sportsman 500), A06CH50FB (Sportsman 500), A07CH50FB (Sportsman 500), A08CH50FB (Sportsman 500), A09CH50FB (Sportsman 500), A10CH50FB (Sportsman 500), A11CH50FB (Sportsman 500), A12CH50FB (Sportsman 500), A03CB50FB (Sportsman 500), A04CB50FB (Sportsman 500), A05CB50FB (Sportsman 500), A06CB50FB (Sportsman 500), A07CB50FB (Sportsman 500), A08CB50FB (Sportsman 500), A09CB50FB (Sportsman 500), A10CB50FB (Sportsman 500), A11CB50FB (Sportsman 500), A12CB50FB (Sportsman 500), A03CH50FC (Sportsman 500), A04CH50FC (Sportsman 500), A05CH50FC (Sportsman 500), A06CH50FC (Sportsman 500), A07CH50FC (Sportsman 500), A08CH50FC (Sportsman 500), A09CH50FC (Sportsman 500), A10CH50FC (Sportsman 500), A11CH50FC (Sportsman 500), A12CH50FC (Sportsman 500), A03CB50FC (Sportsman 500), A04CB50FC (Sportsman 500), A05CB50FC (Sportsman 500), A06CB50FC (Sportsman 500), A07CB50FC (Sportsman 500), A08CB50FC (Sportsman 500), A09CB50FC (Sportsman 500), A10CB50FC (Sportsman 500), A11CB50FC (Sportsman 500), A12CB50FC (Sportsman 500), A02CH50AA (Xplorer 500), A02CH50AB (Xplorer 500), A02CH50AC (Xplorer 500), A02CH50AD (Xplorer 500), A02CH50AE (Xplorer 500), A02CH50AF (Xplorer 500), A02CH50AG (Xplorer 500), A02CH50AH (Xplorer 500), A03CH50FB (Xplorer 500), A04CH50FB (Xplorer 500), A05CH50FB (Xplorer 500), A06CH50FB (Xplorer 500), A07CH50FB (Xplorer 500), A08CH50FB (Xplorer 500), A09CH50FB (Xplorer 500), A10CH50FB (Xplorer 500), A11CH50FB (Xplorer 500), A12CH50FB (Xplorer 500)

👋 Introduction

Segment:

Utility/Recreational All-Terrain Vehicle (ATV)

Target User:

Off-road enthusiasts, farmers, hunters, recreational riders requiring robust and reliable utility vehicles.

Competitors:

Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Suzuki KingQuad, Kawasaki Brute Force/Prairie.

Features:

Long-travel suspension, powerful 4-stroke engines, selectable 2WD/4WD, cargo racks, robust chassis, comfort and utility focus.

Purpose:

To provide comprehensive guidance for maintenance, repair, and restoration of Polaris Sportsman 400, 500, and Xplorer 500 ATVs.

📋 Manual Details

Applicable Years:

2002-2012 (Specific model years may vary by sub-model and region; extensive coverage across this range is typical for such manuals)

Estimated Pages:

Hundreds (as stated, typically 400-700+ pages for comprehensive service manuals covering multiple variants)

Type:

Service Repair Manual

Language:

English

Format:

Digital (PDF Download)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, rebuild procedures, piston, rings, cylinder, crankshaft, connecting rods, camshaft, valves, timing, lubrication system, cooling system.

Fuel System:

Fuel pump, carburetor (or EFI components), fuel filter, fuel lines, fuel tank, fuel system diagnostics.

Ignition System:

Ignition coils, spark plugs, CDI unit, timing, troubleshooting.

Drivetrain Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) removal, disassembly, assembly, inspection, belt replacement, clutch system (primary and secondary), final drive, differential.

Suspension Steering:

Front and rear suspension (A-arms, shocks, springs), steering system (handlebar, steering shaft, tie rods, knuckles), wheel bearings, alignment.

Braking System:

Hydraulic brake system, brake calipers, brake pads, brake lines, master cylinder, brake fluid, parking brake, bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, fuses, relays, ignition switch, control modules.

Bodywork Frame:

Frame inspection and repair, body panels, fenders, racks, seat, plastics, decals, lighting fixtures.

Cooling System:

Radiator, fan, coolant, hoses, thermostat, water pump, flush and fill procedures.

Maintenance Schedules:

Regularly scheduled maintenance intervals (e.g., oil changes, filter replacements, lubrication points, valve adjustments, belt checks).

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, fault finding charts, error codes.

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits, component identification, connector pinouts.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Special Tools:

Identification and usage instructions for specialized tools required for certain procedures.

Specifications Data:

All essential technical data, measurements, tolerances, and specifications for all vehicle systems.

Depth:

Comprehensive (covers basic maintenance through complete engine and transmission rebuilds, electrical diagnostics, and frame repair)

📊 Manual Specifications

Format:

PDF

Searchability:

Text-searchable (typically, depending on PDF creation)

Quality:

High-resolution images and diagrams, printable pages

Binding:

Not Applicable (Digital Download)

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-Stroke, Liquid-Cooled, SOHC, 2-Valve (Typical for these models, variations exist)

Displacement 400:

Approx. 375cc - 400cc (Exact displacement varies by specific model year and sub-model)

Displacement 500:

Approx. 499cc - 500cc (Exact displacement varies by specific model year and sub-model)

Horsepower Range:

Typically in the 25-35 HP range, depending on engine size and tuning.

Torque Range:

Engine torque is optimized for low-end pulling power and trail riding.

Carburetor Type:

Mikuni BSR series (common) or Keihin, specific size varies by model and year.

Fuel Injection:

Some later models may feature Electronic Fuel Injection (EFI).

Oil Type Recommendation:

SAE 10W-40 or SAE 5W-50 Synthetic ATV Oil (Always refer to manual for specific API rating/classification)

Oil Capacity:

Approximately 2.0 - 2.5 quarts (1.9 - 2.4 liters) with filter change (Refer to manual for exact capacity)

Spark Plug Type:

NGK CR7E or similar (Specific type and gap are critical and detailed in the manual)

🔧 Transmission

Transmission Type:

Polaris Variable Transmission (PVT) Automatic with Engine Braking

Drive Modes:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive (2WD/AWD On-Demand)

Clutch System:

Heavy-duty CVT system with primary (drive) and secondary (driven) clutches, belt-driven.

Belt Maintenance:

Critical inspection for wear, cracks, and proper tension; replacement intervals are key.

📐 Dimensions

Length:

Approx. 81-83 inches (205-211 cm)

Width:

Approx. 46-48 inches (117-122 cm)

Height:

Approx. 48-50 inches (122-127 cm)

Dry Weight:

Approx. 550-650 lbs (250-295 kg)

Ground Clearance:

Approx. 10-12 inches (25-30 cm)

Front Rack Capacity:

Approx. 100 lbs (45 kg)

Rear Rack Capacity:

Approx. 200 lbs (90 kg)

Towing Capacity:

Typically 1,200 - 1,500 lbs (544 - 680 kg)

🛡️ Safety Features

Atv Safety Standards:

Complies with ANSI and SFIA standards for ATVs.

Engine Braking:

PVT system provides effective engine braking on descents.

On Demand AWD:

Electronic control for switching between 2WD and 4WD for optimal traction.

Ergonomics:

Handlebar design, seating position, and controls are engineered for rider comfort and control.

Lighting:

Dual headlights, tail light/brake light for visibility.

Braking:

Hydraulic disc brakes on all wheels for reliable stopping power.

💡 Technology Features

Display Features:

Digital instrumentation cluster with speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights (varies by trim).

Adc:

Active Descent Control (ADC) available on some models for controlled downhill braking.

Eps:

Electronic Power Steering (EPS) available on higher-trim models for reduced steering effort.

Usb Charging:

Some models may feature a 12V accessory outlet or USB charging port.

🔧 Maintenance

Engine Oil Change:

Every 100 hours or 6 months (whichever comes first)

Air Filter Cleaning Inspection:

Every 25 hours or monthly; replace as needed.

Spark Plug Check:

Every 100 hours or annually.

Transmission Belt Inspection:

Every 50 hours or annually; check for wear and damage.

Brake Fluid Flush:

Every 2 years or as recommended.

Engine Oil Specification:

Polaris branded 5W-50 Synthetic or equivalent API SG, JASO MA approved oil.

Coolant Type:

Ethylene glycol based antifreeze, 50/50 mix with distilled water. Polaris recommends their specific coolant.

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Cvt Belt Wear:

Premature belt wear can occur with aggressive riding, improper belt tension, or misalignment. Manual details inspection and replacement.

Carburetor Issues:

Clogging or tuning issues, especially if fuel is left in the carb for extended periods. Fuel stabilizer is recommended.

Suspension Bushings:

Wear on A-arm bushings can lead to play and steering looseness. Regular inspection and replacement are advised.

📚 Vehicle History

Manufacturer:

Polaris Industries, Inc. - a long-standing leader in the powersports industry, known for innovation in ATVs and snowmobiles.

Lineage:

The Sportsman line is Polaris's flagship utility ATV series, evolving significantly over the years to incorporate advancements in engine technology, suspension, and ergonomics. The 400, 500, and Xplorer 500 models represent key iterations within this popular family.

Production Period:

These models were in production through various iterations from the early 2000s through to the early 2010s.

Manufacturing Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Atv Of The Year:

While specific awards vary by year, the Polaris Sportsman line has consistently been recognized for its utility, performance, and rider comfort, often ranking highly in industry reviews and buyer satisfaction surveys.