Model:
Sportsman Explorer
Engine Variant:
400 4x4, 500 4x4
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Product Type:
Workshop Service Repair Manual
Target Audience:
Owners of Polaris Sportsman Explorer 400 and 500 4x4 ATVs from 1996-2003 seeking to perform their own maintenance and repairs.
Manual Value Proposition:
Provides comprehensive, professional-level repair data that would typically only be available to dealerships, empowering owners with essential technical knowledge.
Ease Of Use:
Emphasizes ease of reading with exploded views, diagrams, and step-by-step instructions, making complex procedures more accessible.
Instant Access:
Instant download format offers immediate access to critical repair information without waiting for physical delivery.
Compatibility:
Compatible with a wide range of PC and Mac operating systems.
Engine Mechanical:
Detailed rebuild procedures for 400cc and 500cc engines, including top-end, bottom-end, cooling system, lubrication system.
Fuel System:
Carburetor adjustment and overhaul, fuel pump operation, fuel tank and lines.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) belt inspection, replacement, and clutch service; final drive, differential, and axle service.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plugs), starter motor, lighting system, accessory wiring.
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake lines, pads, and rotors.
Suspension Steering:
Front and rear suspension components, shocks, bushings, ball joints, tie rods, steering mechanism.
Chassis Frame:
Frame inspection and repair, bodywork components, plastics, and seating.
Cooling System:
Radiator, fan, coolant flow, water pump.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, tire pressure checks, brake checks.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems.
Overhaul:
Complete engine and transmission overhaul procedures.
Disassembly Reassembly:
Detailed instructions with exploded views for component removal and installation.
Depth:
Comprehensive workshop-level detail, suitable for professional mechanics and experienced DIY enthusiasts.
Illustrations:
Numerous clear illustrations, diagrams, and exploded views for visual guidance.
Specifications:
Detailed torque specifications, clearances, fluid capacities, electrical component resistance, and alignment data.
File Type:
PDF (Portable Document Format)
Searchable:
Likely searchable text within the PDF, enhancing ease of information retrieval.
Printability:
Designed for printing, allowing users to print specific sections or the entire manual for hands-on use.
Delivery Format:
Instant Download (Digital Product)
Digital Medium:
Digital PDF file
Engine Type 400:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (exact displacement varies by specific model year within the range, likely around 375-400cc)
Engine Type 500:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (likely 499cc)
Horsepower Estimated 400:
Approximately 25-30 HP (varies by year)
Horsepower Estimated 500:
Approximately 30-35 HP (varies by year)
Torque Estimated:
Torque figures will be detailed in the manual for each engine variant.
Carburetor Type:
Mikuni CV carburetor (specific model dependent on engine size and year, e.g., Mikuni BSR series).
Fuel Type:
Unleaded gasoline
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with High/Low/Neutral/Reverse range.
Gear Reduction:
Integrated into the CVT and final drive systems.
Drive System:
On-demand 4x4 (AWD) system, often with automatic engagement based on wheel slip.
Gear Ratios:
Continuously variable ratios within the CVT, plus fixed ratios for High, Low, and Reverse ranges. Detailed in manual.
Length:
Specific dimensions for each model year and variant will be detailed in the manual (typically around 80-85 inches).
Width:
Specific dimensions will be detailed (typically around 45-48 inches).
Height:
Specific dimensions will be detailed (typically around 45-50 inches).
Dry Weight:
Typically in the range of 550-650 lbs, depending on the specific model and features. Exact weights will be in the manual.
Ground Clearance:
Typically around 8-10 inches. Specifics will be in the manual.
Rack Capacity Front:
Standard racks with weight capacity will be specified in the manual.
Rack Capacity Rear:
Standard racks with weight capacity will be specified in the manual.
Atv Safety Standards:
Adherence to relevant ATV safety guidelines and regulations for the period of manufacture.
Braking System:
Hydraulic disc brakes (often multiple discs, e.g., dual front, single rear) offering reliable stopping power.
All Wheel Drive:
On-demand 4x4 system enhances traction and stability in challenging terrain.
Chassis Design:
Sturdy frame and overall ATV construction designed for off-road use.
Display Panel:
Likely a basic instrument cluster with speedometer, odometer, fuel gauge, and indicator lights. Advanced infotainment systems were not common on ATVs of this era.
Awt Engagement:
On-demand All-Wheel Drive system provides automatic traction enhancement.
Accessory Power:
Provision for accessory power outlets (e.g., for GPS, charging) may be present, details in manual.
Oil Change Interval:
Typically every 100 hours or annually. Specific details and oil type will be in the manual.
Air Filter Cleaning:
Recommended every 20-40 hours of operation, or more frequently in dusty conditions. Detailed cleaning/replacement in manual.
Spark Plug Replacement:
Intervals will be specified, often around 250-500 hours or annually. Manual will list correct part numbers.
Engine Oil Type:
Typically SAE 10W-40 or 20W-50, synthetic blend or full synthetic. Manual will specify exact viscosity and API classification (e.g., API SG or higher).
Transmission Gearcase Oil:
Specific gear oil or CVT fluid will be listed in the manual. Likely a specialized ATV transmission fluid.
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Manual will specify type and capacity.
Cvt Belt Wear:
CVT belts can wear over time and require inspection for cracks, fraying, and proper thickness. Replacement is a common maintenance item.
Carburetor Clogging:
Carburetors can become clogged with debris or ethanol-related issues, requiring cleaning and adjustment.
Suspension Component Wear:
Ball joints, bushings, and tie rods can wear from off-road use, affecting steering and alignment. Manual provides inspection and replacement guidance.
Polaris Atv History:
Polaris is a long-standing manufacturer of ATVs, known for innovation and ruggedness in the powersports industry.
Sportsman Lineage:
The Sportsman line, introduced in 1993, became a benchmark for comfort, ride quality, and utility in the ATV market. The Explorer sub-model offered enhanced features or a specific design focus within the Sportsman family.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
