🏷️ Basic Information

Make:

Polaris

Model:

Sportsman Xplorer 500 / Sportsman 500 / Xplorer 500 / Worker 500

Model Variants:

Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 400 DUSE, Sportsman 400 Desert, Sportsman 500 Remington Special Edition, Sportsman 400 ASEI, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom

Production Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Target Audience:

DIY enthusiasts and experienced professional mechanics seeking comprehensive repair and maintenance information.

Value Proposition:

Provides an inexpensive way to maintain and repair ATVs, empowering owners to perform tasks themselves and save on labor costs.

Content Quality:

100% complete and intact, no missing or corrupt pages, detailed illustrations, exploded diagrams, drawings, and photos.

Delivery Method:

Instant download, no shipping costs or waiting time.

📋 Manual Details

Covered Models:

Polaris Sportsman 500, Polaris Xplorer 500, Polaris Worker 500, and various special editions including RSE, DUSE, H.O., and Remington Special Editions across the specified model years.

Total Pages:

504

Type:

Official Service and Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Powertrain:

Engine top end, engine lower end, fuel system (carburetion), cooling systems, clutch/drive belt system, transmission, final drive.

Chassis And Body:

Front suspension and steering, rear suspension, brakes, body, wiring diagrams.

Repair And Rebuild:

Complete tear down and rebuild of all major components, detailed step-by-step repair procedures.

Maintenance And Tuneup:

Lubrication, maintenance schedules, tune-up procedures, diagnostic and repair procedures.

Troubleshooting:

Comprehensive troubleshooting guides for common and complex issues.

Depth:

Extremely detailed, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostic procedures and specifications.

📊 Manual Specifications

Digital Format:

PDF

Printable:

Fully printable pages

Digital Binding:

Bookmarked and searchable for easy navigation

Digital Paper Simulation:

Simulates high-quality, professional paper documentation with detailed illustrations and diagrams.

Software Requirements:

Adobe PDF Reader, WinZip (for extraction if compressed)

Operating Systems:

All versions of Windows and Mac

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (typical for this era and model range).

Displacement:

499cc (for 500cc models). 400cc for 400cc models.

Bore X Stroke:

Specifics will be detailed in the manual, typically around 93.2 mm x 73.6 mm for 500cc models.

Fuel Delivery:

Carbureted (specific carburetor model and settings detailed in manual, e.g., Mikuni BSR42).

Fuel Type:

Unleaded gasoline (regular octane, typically 87).

Ignition System:

CDI (Capacitor Discharge Ignition) with electronic advance.

Cooling System:

Liquid-cooled with fan assist.

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse.

Drive System:

Shaft drive to front and rear differentials, On-Demand AWD (All-Wheel Drive) typically engaged electronically.

Clutch System:

Automatic centrifugal clutch and drive/driven pulleys for CVT operation.

📐 Dimensions

Length:

Varies slightly by year and model, typically around 82-85 inches.

Width:

Typically around 46-48 inches.

Height:

Typically around 46-48 inches.

Dry Weight:

Varies by model, generally in the 600-700 lbs range.

Cargo Capacity Rack Front:

Typically rated around 90 lbs.

Cargo Capacity Rack Rear:

Typically rated around 180 lbs.

Towing Capacity:

Typically rated around 1,500 lbs.

Fuel Capacity:

Typically 3.2-3.7 gallons (including reserve).

🛡️ Safety Features

Atv Safety Standards:

Designed to meet or exceed industry safety standards for ATVs of its era.

Braking System:

Hydraulic disc brakes on all wheels (typically 3 or 4 wheels depending on configuration and year), hand and foot brake controls.

Lighting:

Headlights, taillight, brake light.

Rollover Protection:

Standard ATV design principles, rider responsibility for safe operation.

Restraint System:

No occupant restraint system (seatbelt). Riders are required to wear helmets and appropriate protective gear.

💡 Technology Features

Display Features:

Basic LCD instrumentation panel displaying speed, odometer, trip meter, 4WD indicator, etc. (specifics vary by year).

Drive Modes:

On-Demand All-Wheel Drive (AWD) system, selectable 2WD/AWD.

Accessories:

Factory pre-wired for accessories, though not considered modern 'connectivity'.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or annually (details in manual).

Air Filter Cleaning:

Recommended at frequent intervals, especially in dusty conditions (details in manual).

Spark Plug Replacement:

Recommended at specified hours or annually (details in manual).

Engine Oil Type:

Polaris specifically recommends its own brand of synthetic ATV engine oil (e.g., 0W-40 or 10W-40, check manual for exact specification).

Gearcase Oil Type:

Polaris Demand Drive Fluid for front differential, Polaris Gearcase Lubricant for rear differential (specific grades and capacities in manual).

Coolant Type:

Ethylene glycol-based antifreeze mixture (typically 50/50 with distilled water, check manual for exact type).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (check manual for specific requirement).

Common Wear Items:

CV boots, tie rod ends, suspension bushings, wheel bearings, starter motor, battery.

Engine Performance:

Carburetor tuning, fuel system cleaning, clutch wear can affect performance. High Output (H.O.) models introduced later offer improved power.

Electrical System:

Stator failures, voltage regulator issues, and wiring harness corrosion can occur over time.

📚 Vehicle History

Manufacturer Origin:

Polaris Industries Inc., founded in Minnesota, USA, known for its history in snowmobiles and expanding into ATVs.

Sportsman Lineage:

The Sportsman line has been a flagship series for Polaris, emphasizing comfort, utility, and reliable performance for trail riding and work.

Manufacturing Location:

Primarily manufactured in the United States by Polaris.

Market Introduction:

The Sportsman 500 was introduced as a significant advancement in ATV technology and comfort for its time.

🏆 Awards & Recognition

Industry Standing:

The Polaris Sportsman line has consistently been a top seller and highly regarded in the ATV market for its balance of features and performance.

Consumer Perception:

Generally positive consumer reviews for durability, comfort, and utility, with specific model years and engine variations receiving higher accolades (e.g., H.O. models).