2000-2003 Polaris Sportsman Xplorer 500 400 4WD ATV Workshop Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer Model Variant: 400 4WD, 500 4WD Year: 2000-2003 Codes Chassis Code: Not specified, typical for ATVs to have component-based identification rather...

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Tipo: Atv

Proveedor:

SKU: 23956

Etiquetas: 2000 2001 2002 2003 400 400 Models 4WD 500 Atv Polaris Powersports Snowmobiles Sportsman Xplorer

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Xplorer

Model Variant:

400 4WD, 500 4WD

Year:

2000-2003

Codes

Chassis Code:

Not specified, typical for ATVs to have component-based identification rather than a single chassis code.

👋 Introduction

Market Position

Positioning:

Premium utility ATV for recreational and demanding off-road use.

Competitive Analysis

Competitors:

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

Key Features

Features:

Powerful engines, robust 4WD systems, independent suspension, advanced ergonomics, cargo racks.

Manual Value Proposition

Value:

Provides authoritative, factory-sourced repair and maintenance data, enabling cost-effective and accurate servicing.

📋 Manual Details

Coverage Areas

Geographical Coverage:

Global (OEM specifications are universally applicable)

Model Year Coverage:

2000, 2001, 2002, 2003

Variant Coverage:

Sportsman Xplorer 400 4WD, Sportsman Xplorer 500 4WD

Page Count

Estimated Page Count:

Likely 300-500 pages (typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Service Repair Manual

Source:

Factory/Official

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnostics, tuning, internal components, lubrication system, cooling system, intake and exhaust systems.

Transmission:

All aspects of transmission repair and maintenance, including clutches, gearboxes, and drive systems.

Drivetrain:

Front and rear differentials, drive shafts, CV joints, 4WD engagement system.

Suspension:

Front and rear suspension components, shock absorbers, control arms, bushings, alignment procedures.

Brakes:

Hydraulic brake systems, calipers, master cylinders, brake lines, bleeding procedures, pad and rotor replacement.

Electrical System:

Wiring diagrams, component testing, starter, alternator/stator, battery, ignition system, lighting, charging system.

Fuel System:

Carburetor overhaul and adjustment (if applicable), fuel pump, fuel lines, fuel tank maintenance.

Cooling System:

Radiator, fan, hoses, coolant specifications, thermostat, water pump.

Frame And Body:

Chassis inspection, body panel removal and installation, seat, handlebars, rack systems.

Procedures Included

Maintenance:

Routine maintenance, lubrication, tune-ups, filter replacements, fluid changes, spark plug service.

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major and minor mechanical and electrical components.

Rebuild:

Major engine and transmission rebuild procedures, including detailed component specifications.

Disassembly Assembly:

Comprehensive instructions for disassembling and reassembling all vehicle systems.

Inspections:

Detailed inspection points and procedures to identify wear and potential failures.

Technical Depth

Depth:

Factory-level repair and diagnostic information.

Audience:

Professional technicians and DIY mechanics with basic to advanced mechanical knowledge.

Content Type:

Detailed instructions, charts, diagrams, illustrations, photos, OEM specifications.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content

Print Quality

Printability:

Printable pages for convenient workshop use.

Binding Type

Binding:

Digital (N/A for PDF download; implies printable format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine 400

Engine Type 400:

4-stroke, SOHC, 4-valve, Single Cylinder

Displacement 400:

375cc (approx.)

Primary Engine 500

Engine Type 500:

4-stroke, SOHC, 4-valve, Single Cylinder

Displacement 500:

499cc (approx.)

Performance

Horsepower Estimate 500:

Approximately 30-35 HP (varies by tuning and exact model year)

Torque Estimate 500:

Approximately 30-35 lb-ft (varies by tuning and exact model year)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni or Keihin, specific model TBD by manual)

Fuel Type:

Unleaded Gasoline, 87 Octane minimum

Cooling System

Cooling Method:

Liquid-cooled

Lubrication

Oil Type:

SAE 10W-40 API SG or higher (Specific Polaris oil recommended, consult manual for exact specs)

Engine Components

Compression Ratio Spec:

Refer to manual for specific OEM compression ranges

🔧 Transmission

Standard

Type:

Automatic (Polaris Variable Transmission - PVT)

Optional

Options:

N/A for this model lineup

Features

Features:

High/Low range gearing, Reverse, Park, Engine braking.

Fluid Specifications

Pvtf Fluid:

Polaris PVT Fluid (P/N 2871147) or equivalent (refer to manual for exact type and capacity)

📐 Dimensions

Exterior

Wheelbase:

Approx. 50.5 inches (1283 mm)

Ground Clearance:

Approx. 9.5 inches (241 mm)

Weights

Dry Weight 500:

Approx. 635 lbs (288 kg)

Dry Weight 400:

Approx. 610 lbs (277 kg)

Cargo

Front Rack Capacity:

Approx. 50 lbs (22.7 kg)

Rear Rack Capacity:

Approx. 100 lbs (45.4 kg)

Towing

Towing Capacity:

Approx. 1500 lbs (680 kg)

🛡️ Safety Features

Ratings

Safety Certification:

ATV industry safety standards (ANSI/SVIA)

Active Features

Braking System:

Hydraulic disc brakes, front and rear.

4Wd System:

On-demand 4WD with ADC (Active Descent Control) on some models/years.

Passive Features

Ergonomics:

Comfortable seating position, easy-to-reach controls.

Lighting:

Dual headlights, taillight/brake light.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic ATV design, focus is on functionality)

Driver Assistance

Driver Assistance Features:

On-Demand AWD, Engine Braking (EBS) on some models.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 100 hours or 12 months, whichever comes first (refer to manual for precise intervals).

Air Filter Maintenance:

Clean every 25 hours, replace as needed.

Spark Plug Replacement:

Check every 100 hours, replace as needed (e.g., NGK CR7E or equivalent).

Fluid Specifications

Coolant Type:

Ethylene glycol based antifreeze (50/50 mix with distilled water). Consult manual for specific Polaris coolant P/N.

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Fluid Capacities

Engine Oil Capacity:

Approx. 2.1 quarts (2.0 Liters) with filter change (verify in manual).

Known Issues

Common Wear Items:

CV boots, tie rod ends, wheel bearings, drive belts (PVT).

Potential Problems:

Carburetor gumming if not stored properly, starter solenoid issues, charging system stator failures.

📚 Vehicle History

Brand Heritage

Heritage:

Polaris is a leading manufacturer of powersports vehicles, known for innovation in ATVs since the 1980s.

Model Evolution

Evolution:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving with enhanced features and performance.

Production

Production Era:

The Xplorer sub-model was part of Polaris' expanded utility ATV range in the late 1990s and early 2000s.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Polaris Sportsman models are consistently recognized for their utility, durability, and performance in the ATV market.