This manual covers the Sportsman Xplorer 500 and its variants, including the Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 500 DUSE, and Sportsman 500 H.O., for the production years 1996 through 2003. These versatile All-Terrain Vehicles (ATVs) are known for their robust single-cylinder, 4-stroke engines, typically 499cc and liquid-cooled, designed for a balance of utility and trail performance. Featuring an automatic Variable Transmission (PVT) with selectable 2WD/4WD and On-Demand All-Wheel Drive, these ATVs offer reliable power delivery for various off-road applications.
This comprehensive service repair manual provides detailed information essential for the maintenance and repair of your Sportsman Xplorer 500. It covers a wide array of systems, including general information, troubleshooting, lubrication, tune-ups, engine components, fuel and cooling systems, transmission, drivetrain, electrical systems, suspension, steering, and brakes. The manual includes step-by-step repair procedures, diagnostic guides, and high-resolution diagrams, making it an invaluable resource for both DIY enthusiasts and professional technicians seeking to keep their vehicle in optimal condition.
Model:
Sportsman Xplorer 500
Model Variant:
Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 H.O.
Chassis Code:
Not specified, but consistent within model years
Engine Code:
Likely variations of the Fuji-Robin or Polaris manufactured 499cc 4-stroke OHV single-cylinder engine, specific codes not provided.
Purpose:
To provide comprehensive service and repair information for the Polaris Sportsman Xplorer 500 ATV, enabling owners and technicians to maintain and repair the vehicle effectively.
Content Advantage:
High-resolution diagrams, easy-to-read text, step-by-step instructions, designed for both DIY and professional users.
Cost Savings:
Inexpensive way to keep the vehicle working properly, avoiding dealer labor costs for repairs and maintenance.
Professional Standard:
Equivalent to the service manual used by local dealers.
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Models Covered Detail:
1996 Sportsman 500; 1997 Sportsman 500, Xplorer 500; 1998 Sportsman 500, Worker 500; 1999 Sportsman 500, Worker 500, Sportsman 500 RSE; 2000 Sportsman 500, Worker 500, Sportsman 500 RSE (Remington Special Edition); 2001 Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O.; 2002 Sportsman 400, Worker 400 (International), Sportsman 400 ASEI, Sportsman 400 DUSE, Sportsman 500 H.O., Worker 500 (International), Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom; 2003 Sportsman 400, Sportsman 500 H.O., Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400 Desert.
Delivery Method:
Instant Download
Compatibility:
All PC based Windows operating systems & Mac
Requirements:
Adobe PDF Reader & WinZip
Type:
Service Repair Manual
Print Quality:
High resolution, excellent print quality for needed pages
Primary Systems:
General Information, Troubleshooting, Lubrication, Maintenance, Tune-Up, Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, Body.
Additional Systems:
2001-2003 Specific Service Information, Wiring Diagrams.
Maintenance Procedures:
Scheduled maintenance, lubrication, fluid changes, filter replacements, tune-ups.
Repair Procedures:
Step-by-step instructions for all major repair areas, engine rebuilds, drivetrain component service, suspension and steering repairs, brake system service, electrical diagnostics and repair, body panel removal and installation.
Diagnostic Procedures:
Troubleshooting guides for common and complex issues, diagnostic flowcharts.
Depth:
Comprehensive; suitable for DIY enthusiasts and professional mechanics. Covers detailed disassembly, reassembly, and adjustment procedures.
Searchable Text:
Implied by PDF format and high quality, likely includes searchable text.
Binding Type:
Digital PDF (printable to CD or individual pages)
Paper Type:
N/A (Digital)
Configuration:
Single-cylinder, 4-stroke, Overhead Valve (OHV)
Displacement:
499cc (for 500 models); 400cc (for 400 models)
Bore X Stroke:
Not specified, but typical for the era and displacement range.
Cooling System:
Liquid-cooled (for most 500 models and some 400s)
Horsepower:
Typically in the range of 25-30 HP, specific figures vary by model year and tuning.
Torque:
Not specified, but designed for low-end torque for utility and trail riding.
Carburetion:
Mikuni Carburetor (specific model not listed, likely BSR series for 500cc). The manual covers carburetion for maintenance and tuning.
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Typically around 3.2 gallons (12.1 liters), varies slightly by year/model.
System:
CDI (Capacitor Discharge Ignition), electronic ignition.
Type:
Automatic (PVT - Polaris Variable Transmission) with centrifugal clutch and belt drive.
Gear Selection:
High, Low, Neutral, Reverse.
Drive System:
Shaft drive to rear axle, with selectable 2WD/4WD and front differential engagement (On-Demand AWD).
Transmission Oil Type:
Polaris Premium 2-Cycle Lubricant (for pre-mix models) or specific PVT fluid/oil as per manual, typically SAE 20W-50 for engine/transmission if combined, or specific PVT fluid. The manual will detail exact requirements.
Length:
Approximately 81 inches (205.7 cm) for Sportsman 500 models, may vary slightly.
Width:
Approximately 46 inches (116.8 cm) for Sportsman 500 models, may vary slightly.
Height:
Approximately 47 inches (119.4 cm) for Sportsman 500 models, may vary slightly.
Dry Weight:
Around 500-550 lbs (227-250 kg), depending on exact model and features.
Towing Capacity:
Typically 1,500 lbs (680 kg).
Ground Clearance:
Approximately 10.5 inches (26.7 cm).
Wheelbase:
Approximately 50.5 inches (128.3 cm).
Braking System:
Hydraulic disc brakes on all wheels (dual front, single rear). Manual covers brake system maintenance and repair.
Tire Specifications:
Front: 25x8-12, Rear: 25x10-12 (common, may vary by trim/year). Manual will specify tire pressure and maintenance.
Rollover Protection:
ATVs are not equipped with integrated rollover protection systems like ROPS found on UTVs or other vehicles. Operation requires rider skill and adherence to safety guidelines.
System:
N/A - basic ATV with focus on function, not infotainment.
Features:
On-Demand All-Wheel Drive (AWD) is a key drivetrain technology. No electronic driver aids like traction control or ABS.
Features:
12V electrical system, CDI ignition, electric start, lighting (headlights, taillight), battery charging system (alternator/stator). Manual provides detailed wiring diagrams.
Oil Change:
Typically every 50-100 hours of operation or annually, whichever comes first. The manual will provide detailed intervals.
Air Filter Maintenance:
Regular inspection and cleaning/replacement, especially in dusty conditions. Specified intervals in manual.
Spark Plug Replacement:
Intervals typically around 100-200 hours or annually. Manual will list correct type and gap.
Drive Belt Inspection:
Regular inspection for wear and damage, replacement recommended every 1-2 years or based on hours/condition. Manual covers inspection and replacement.
Engine Oil Type:
Typically SAE 20W-50 API SG or higher. Manual will specify exact viscosity and API classification.
Coolant Type:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio). Manual specifies type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify.
Common Problems:
Drive belt wear, starter solenoid issues, carburetor adjustments, charging system components (stator, voltage regulator), and occasional cooling system leaks are common for ATVs of this era. The manual addresses troubleshooting and repair for these.
Manufacturer:
Polaris Industries Inc.
Introduction:
The Polaris Sportsman line was introduced in the early 1990s, with the 500cc engine becoming a staple. The Xplorer was often a slightly more specialized variant, and the 500cc platform was widely adopted and refined through these years.
Key Variants:
RSE (Remington Special Edition) featured camouflage, DUSE (Ducks Unlimited Special Edition) also had unique graphics. H.O. (High Output) models often indicated engine refinements or tuning for increased performance. Worker models were typically geared towards utility/work applications.
Manufacturing Location:
Primarily USA (Minnesota).
Awards:
No specific awards are mentioned for this manual or the models it covers, but Polaris ATVs of this era were generally well-regarded for their utility and performance in the off-road market.
