Target Audience:
Owners, technicians, and repair shops seeking detailed information for the Polaris Sportsman 400/500 Xplorer.
Value Proposition:
Provides dealer-level repair information at a fraction of the cost of dealership services or physical manuals.
Digital Access:
Instant PDF download for immediate access, eliminating shipping delays and costs.
Engine:
Engine overhaul, disassembly, inspection, assembly, specifications, tuning, and troubleshooting.
Transmission:
Automatic transmission operation, maintenance, repair, and troubleshooting.
Drivetrain:
Driveshaft, differential, axle repairs, and maintenance.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, and pivot points.
Steering:
Steering column, tie rods, steering linkage, and maintenance.
Brakes:
Hydraulic brake system, calipers, brake lines, master cylinder, and bleeding procedures.
Electrical System:
Wiring diagrams, ignition system, charging system, starter, lighting, and accessory circuits.
Fuel System:
Fuel tank, fuel pump, carburetor (or fuel injection for specific models/years), and fuel lines.
Cooling System:
Radiator, fan, coolant, and thermostat maintenance and repair.
Exhaust System:
Muffler, exhaust pipes, and catalytic converter (if applicable).
Bodywork:
Body panel removal and installation, seat, handlebars, and fender repairs.
Maintenance:
Routine service, oil changes, filter replacements, lubrication, and general upkeep.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common and uncommon issues.
Repair:
Step-by-step instructions for component replacement and repair across all systems.
Rebuild:
Complete engine and transmission rebuild procedures with detailed specifications.
Diagnostics:
Advanced diagnostic techniques for electrical and mechanical problems.
Depth Level:
Comprehensive, covering everything from basic maintenance to complete engine overhauls and complex electrical diagnostics.
Engine Type:
4-stroke, Liquid-Cooled, SOHC, 2-Valve
Bore X Stroke:
83 x 71.4 mm
Horsepower Approx:
25-28 HP
Torque Approx:
27-29 lb-ft
Engine Type:
4-stroke, Liquid-Cooled, SOHC, 2-Valve
Bore X Stroke:
92.3 x 71.4 mm
Horsepower Approx:
33-36 HP
Torque Approx:
35-38 lb-ft
Carburetion:
Mikuni BSR (specific model/year variants may exist, covered in manual)
System Type:
Electronic Ignition (CDI)
Type:
Automatic PVT (Polaris Variable Transmission) with Hi/Lo range and Reverse
Engagement:
Shaft Drive (AWD/2WD selectable on some models, check manual for specifics)
Clutch Type:
Primary and Secondary CVT clutches
Belt Inspection Interval:
Recommended at 100-hour or 1,200-mile intervals (refer to manual for exact spec)
Length In:
Approx. 83 inches (varies slightly by model year)
Width In:
Approx. 46 inches (varies slightly by model year)
Height In:
Approx. 49 inches (varies slightly by model year)
Dry Weight Lbs:
Approx. 550-600 lbs (varies by model/trim)
Ground Clearance In:
Approx. 8-10 inches (varies by model/trim)
Rack Capacity Front Lbs:
Approx. 90 lbs
Rack Capacity Rear Lbs:
Approx. 170 lbs
Front Tire Size:
25x8-12 (common)
Rear Tire Size:
25x10-12 (common)
Wheel Bolt Pattern:
4x110 mm (typical for Polaris ATVs of this era)
Display Features:
Basic digital/analog instrument cluster with speedometer, odometer, fuel gauge, and indicator lights.
Traction Control:
N/A (No advanced electronic driver-assistance systems like traction control in this generation).
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or USB ports).
Engine Oil Change:
Every 100 hours or annually, whichever comes first.
Gearcase Oil Change:
Annually or every 100 hours.
Spark Plug Check Replace:
Check every 100 hours, replace as needed.
Air Filter Cleaning:
Inspect and clean every 20-30 hours, replace as needed.
Engine Oil Type:
SAE 10W-40, API SG or higher (e.g., Polaris Premium 4 Synthetic 10W-40).
Engine Oil Capacity Qts:
Approx. 2.1 quarts (refer to manual for exact capacity with filter change).
Gearcase Oil Type:
SAE 80W-90 GL-5 Gear Lube (e.g., Polaris Gearcase Lube).
Gearcase Oil Capacity Ml:
Approx. 355 ml (Front & Rear Differentials).
Brake Fluid Type:
DOT 3 Brake Fluid.
Cv Joint Wear:
CV joint boots can tear, leading to premature wear. Regular inspection is recommended.
Charging System Rectifier:
Rectifier/regulator failure can lead to battery charging issues.
Starter Solenoid:
Starter solenoid can become faulty, preventing engine cranking.
Carburetor Cleaning:
Carburetors may require periodic cleaning due to fuel quality or debris ingress.
Suspension Bushings:
Wear in suspension bushings can lead to looseness and noise.
Manufacturer Focus:
Polaris Industries is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, utility, and off-road capability. This generation introduced significant advancements in suspension and engine technology for its time.
Manufacturing Location:
Primarily manufactured in the USA.
