Model Variant:
Xplorer 500
Engine Displacement:
499cc
Engine Type:
Four-stroke, SOHC, liquid-cooled, single-cylinder
Fuel Type:
Unleaded Gasoline
Drive Type:
All-Wheel Drive (AWD)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking
Vin Decoder Notes:
VIN decoding information not explicitly provided in product data, but typically follows industry standards for ATV manufacturers. Specific details would be in the manual.
Target Audience:
Owners of Polaris Sportsman 500 and Xplorer 500 ATVs from 1996-2003 seeking to perform maintenance, repairs, and diagnostics.
Value Proposition:
Provides professional-level repair and maintenance information, enabling users to save on repair costs and maintain their vehicle's condition. Offers comprehensive coverage for a wide range of models and years.
Content Depth:
In-depth and highly detailed, covering the entire vehicle from start to finish.
Usability:
Easy to use, with step-by-step instructions. Available for instant download.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Specific Models Covered:
Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 400 ASEI, Sportsman 400 DUSE, Worker 400 (International), Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom, Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400 Desert
Estimated Page Count:
Approximately 450+ pages (based on typical workshop manual depth and provided index)
Type:
Workshop Service Repair Manual
Format:
Digital Download (PDF)
Powertrain:
Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System
Chassis And Suspension:
Front Suspension and Steering, Rear Suspension, Brakes
Electrical And Body:
Electrical System, Body
Maintenance:
Pre-ride checks, periodic lubrication, tire maintenance, battery care, tune-ups, fluid changes, filter replacements, component cleaning and inspection
Troubleshooting:
Engine starting difficulties, charging system issues, ignition system problems, fuel system malfunctions, overheating, engine noises, power train issues, steering problems, frame noise, brake system faults
Repair And Rebuild:
Engine internal component replacement (pistons, rings, valves, camshaft, crankshaft), carburetor overhaul, clutch and drive belt service, transmission disassembly and assembly, brake caliper and master cylinder service, suspension component replacement, electrical component diagnosis and replacement
Diagnostics:
Cylinder leak down testing, charging system testing, ignition system testing, electronic throttle control diagnostics, carburetor performance tests
Depth:
Comprehensive; covers basic maintenance, routine servicing, advanced diagnostics, complete component overhauls, and full vehicle rebuilds. Designed for professional mechanic use.
Quality:
High-resolution, designed for clear viewing and printing of text and diagrams. Printable for hardcopy.
Binding:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Searchability:
Likely searchable text within the PDF for quick information retrieval.
Illustrations:
Includes highly detailed exploded pictures and diagrams.
Engine Configuration:
499cc, SOHC, 4-valve, liquid-cooled, single-cylinder
Horsepower Range:
Typically around 30-34 HP (varies by specific year and H.O. designation).
Torque Specifications:
Detailed torque specifications for all engine components are provided in the manual.
Carburetor Type:
Mikuni BSR42 (common for many 500cc models), specific carburetor details, cleaning, and adjustment procedures are covered.
Fuel Delivery:
Gravity feed with a fuel pump system.
Type:
Liquid-cooled with a radiator, fan, and coolant pump.
Type:
CDI (Capacitor Discharge Ignition) with detailed ignition timing and component testing.
Transmission:
Polaris Variable Transmission (PVT) with automatic centrifugal clutch and belt drive.
Transmission Options:
Not applicable, PVT is standard across these models.
Engine Braking:
Integrated engine braking system for downhill control.
Fluid Type:
Specific transmission fluid requirements (likely Polaris AGL or similar) are detailed in the manual.
Drive Belt:
Service, inspection, and replacement procedures for the drive belt are extensively covered, including clutch alignment and tensioning.
Atv Safety Standards:
The manual emphasizes safety precautions throughout its instructions, aligning with general ATV safety guidelines.
Braking System:
Hydraulic disc brakes front and rear. Detailed service procedures for calipers, master cylinders, and bleeding are included.
Frame Construction:
Robust chassis design for stability. Frame noise troubleshooting is covered.
Oil Change Interval:
Typically every 100 hours or annually. Specific intervals for engine oil, transmission oil, and front differential oil are detailed.
Drive Belt Inspection:
Recommended inspection intervals for wear and tension are provided.
Engine Oil Type:
Specific viscosity and API service classification (e.g., SAE 20W-50 or 0W-40, API SG or higher) are detailed for different operating temperatures.
Transmission Fluid Type:
Polaris AGL Gearcase Lubricant or equivalent is typically specified.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Common Wear Items:
Drive belts, brake pads, wheel bearings, ball joints, and tie rod ends are common wear items addressed in the maintenance and troubleshooting sections.
Charging System Concerns:
The manual provides troubleshooting steps for potential issues with the stator and voltage regulator.
Spark Plug Replacement:
Specifications for spark plug type, gap, and replacement intervals are provided.
Polaris Atv Legacy:
Polaris has a long-standing reputation for producing reliable and capable ATVs, with the Sportsman line being a cornerstone of their off-road offerings.
Sportsman Development:
The Sportsman 500 was a highly successful model, known for its powerful engine, independent rear suspension, and AWD capabilities, evolving through various trim levels and minor updates during this period.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
