Category:
All-terrain vehicle (ATV) utility/recreational.
Competitors:
Competed against models from Honda (FourTrax), Yamaha (Grizzly), Suzuki (KingQuad), and Kawasaki (Bayou/Prairie) during its production run.
Features:
Known for its capable 4x4 system, comfortable ride, and versatility for both work and recreation. The Xplorer branding emphasized its off-road and utility capabilities.
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Estimated Page Count:
Typically 500+ pages for a complete workshop manual covering multiple model years and variants.
Type:
Complete Workshop Service Repair Manual
Engine:
Detailed diagnosis, repair, and overhaul procedures for all engine components, including top-end, bottom-end, cooling, and lubrication systems.
Transmission Drivetrain:
Coverage of the AWD system, final drive, driveshafts, differential, and related components. Procedures for repair, adjustment, and fluid service.
Fuel System:
Carburetor (for applicable models), fuel pump, fuel tank, fuel lines, and associated filters and components. Includes cleaning, adjustment, and troubleshooting.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor, and troubleshooting common electrical faults.
Brakes:
Hydraulic brake system, including master cylinders, calipers, brake lines, pads, rotors, and bleeding procedures. Focus on front and rear brake systems.
Suspension Steering:
Front and rear suspension components (shocks, A-arms, bushings), steering system (tie rods, steering shaft, components), and wheel alignment procedures.
Chassis Frame:
Frame inspection, repair considerations, body panels, fenders, racks, and seat mounting.
Cooling System:
Radiator, fan, hoses, thermostat, and coolant specifications and maintenance.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug checks, lubrication points, and fluid level checks.
Troubleshooting:
Diagnostic procedures for common problems, including symptoms, causes, and step-by-step solutions.
Repair:
Detailed step-by-step repair instructions for virtually all components and systems.
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, inspection, part replacement, and reassembly.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for easy diagnosis and repair.
Specifications:
Torque specifications, clearances, measurements, and adjustment procedures for all major components.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
Engine Type 400:
4-stroke, Liquid-cooled, Single Cylinder (likely SOHC)
Engine Displacement 400:
Approx. 375cc - 400cc (specific displacement may vary by exact sub-model and year; official specs would confirm. Early models often around 375cc, later might be closer to 400cc).
Engine Type 500:
4-stroke, Liquid-cooled, Single Cylinder (likely SOHC)
Displacement 500:
Approx. 499cc (specific displacement may vary by exact sub-model and year; official specs would confirm. Likely a 500cc class engine).
Horsepower Range:
Estimates vary, but typically in the range of 25-35 HP for these models, depending on engine size and tuning.
Torque Range:
Provides good low-end torque for pulling and climbing. Specific figures depend on engine size and configuration.
Fuel Delivery:
Carbureted. Specific carburetor model and jetting would be detailed in the manual.
Fuel Type:
Unleaded gasoline
Cooling Method:
Liquid-cooled
Length:
Typical for this era of utility ATV, around 80-85 inches (203-216 cm).
Width:
Typically around 45-48 inches (114-122 cm).
Height:
Typically around 46-48 inches (117-122 cm).
Dry Weight:
Around 550-650 lbs (250-295 kg) depending on model and features. Specific figures require manual lookup.
Ground Clearance:
Typically 9-11 inches (23-28 cm) for good off-road capability.
Rack Capacity Front:
Typically rated for around 50-100 lbs (23-45 kg).
Rack Capacity Rear:
Typically rated for around 100-150 lbs (45-68 kg).
Towing Capacity:
Typically rated for around 600-1000 lbs (272-454 kg), often with a 1.25-inch receiver hitch standard or optional.
Atv Safety Standards:
Adheres to ANSI standards for ATVs. Features like thumb throttle control for modulated acceleration and brake lever placement for control are inherent safety elements.
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Throttle Control:
Thumb-operated throttle lever for precise control.
Lighting:
Headlights, taillight/brake light for visibility.
Rollover Protection:
Standard ATV design without integrated rollover protection systems common on side-by-sides. Operator awareness and training are critical.
Features:
Basic instrumentation: speedometer, odometer, hour meter, fuel gauge (if equipped), indicator lights for 4WD, oil pressure, etc. No advanced infotainment systems.
Features:
No electronic driver assistance systems (e.g., ABS, traction control) present in these models. Control is entirely mechanical and rider-dependent.
Features:
No connectivity features available.
Engine Oil Change:
Typically every 50-100 hours of operation or annually, whichever comes first. Check manual for specific intervals.
Air Filter Inspection:
Inspect frequently, clean or replace as needed based on operating conditions (e.g., dusty environments).
Spark Plug Service:
Check and gap every 50-100 hours, replace as needed. Specific plug type is critical.
Cv Belt Inspection:
Inspect for wear and damage periodically, especially if experiencing slippage or performance issues. Replacement is a common repair.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 motorcycle/ATV specific oil (check manual for exact recommendation).
Engine Oil Capacity:
Approximately 1.5 - 2.0 quarts (1.4 - 1.9 liters). Check manual for precise capacity.
Coolant Type:
Ethylene glycol-based antifreeze solution mixed with distilled water (typically 50/50). Check manual for specific formulation.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Gearcase Oil:
Specific gear oil or SAE 80W-90 GL-5 hypoid gear lubricant (check manual for exact recommendation and capacity).
Common Problems:
Common issues for ATVs of this era can include carburetor tuning issues, CVT belt wear, aging electrical components (stator, rectifier), water pump seal leaks, and suspension component wear (bushings, ball joints).
Cv System Maintenance:
Regular inspection and replacement of the CVT belt are crucial for maintaining performance and preventing drivetrain damage. Clutch weights and springs can also wear.
Polarist Atv Legacy:
Polaris has a long history in ATVs, pioneering many features and becoming a dominant force in the off-road vehicle market. The Sportsman line is a cornerstone of their ATV offerings.
Sportsman Line Development:
The Sportsman line evolved through various engine sizes and feature sets, with the Xplorer designation often indicating enhanced off-road or touring capabilities. The 400 and 500 models were popular mid-to-large displacement options.
Manufacturing Location:
Primarily manufactured in the USA by Polaris.
Key Production Period:
1996-2003 covers a significant era for these models, reflecting advancements in ATV technology during that time.
