Model Variants Covered:
Sportsman 400, Sportsman 500, Sportsman RSE, Sportsman DUSE, Sportsman H.O., Worker 500, Xplorer 500
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Vin Structure General Note:
Not specified in product information, but VIN decoding would typically be covered in a service manual.
Target Audience:
DIY enthusiasts, ATV owners, mechanics, and workshops seeking professional-level repair and maintenance information.
Value Proposition:
Saves money on repairs by empowering owners to perform their own maintenance and fixes. Provides professional-grade information for DIY users.
Access:
Instant download after payment.
Usage Rights:
Can be saved on multiple devices, no time limit for use after download.
Support:
Free support available for download issues.
Primary Coverage:
Comprehensive service, repair, maintenance, and troubleshooting for Polaris Sportsman 400 and 500 series ATVs from 1996-2003.
Specific Models Detailed:
Sportsman 500 (2001-2003), Sportsman 400 (2001-2003), Worker 500, Sportsman RSE, Sportsman DUSE, Sportsman H.O., Xplorer 500 (1997).
Type:
Service Manual / Workshop Manual / Repair Guide
Engine Mechanical:
Engine overhaul, top-end rebuild, piston and ring replacement, cylinder head service, valve adjustment, camshaft inspection, timing chain/belt maintenance.
Engine Fuel System:
Carburetor service and adjustment (including jetting), fuel pump testing and replacement, fuel filter maintenance, fuel tank inspection.
Engine Ignition System:
CDI unit testing, ignition coil inspection, spark plug selection and gapping, stator and rotor testing.
Transmission Drivetrain:
Primary drive system (clutch), secondary drive system (belt drive), gearcase lubrication and inspection, drive shaft maintenance, CV joint service.
Braking System:
Brake caliper service and rebuild, brake pad replacement, brake fluid bleeding and replacement, master cylinder inspection, hydraulic line maintenance.
Suspension Steering:
Front and rear suspension component inspection and replacement (shocks, springs, control arms), steering system lubrication and adjustment, tie rod end service.
Electrical System:
Wiring diagrams, battery testing and maintenance, starter motor service, charging system (alternator/stator) testing, lighting system troubleshooting, switch and relay testing.
Cooling System:
Radiator inspection and cleaning, coolant type and capacity, thermostat testing, water pump service, fan operation.
Bodywork Frame:
Body panel removal and installation, seat maintenance, rack systems, frame inspection for damage.
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug replacement, drive belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and mechanical issues. Symptom-based troubleshooting guides.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly (e.g., engine rebuild, carburetor overhaul).
Diagnostics:
Methods for diagnosing faults within various vehicle systems, including electrical testing and mechanical checks.
Depth:
Comprehensive. Covers everything from basic user maintenance to full engine and transmission rebuilds, electrical system diagnostics, and detailed troubleshooting.
Scope:
Factory-level service information, equivalent to what professional technicians use.
Diagrams Illustrations:
Includes clear, step-by-step instructions with illustrations, wiring diagrams, and component breakdowns.
Compatibility:
Compatible with all operating systems (Windows, Linux, Mac), viewable with any PDF reader.
Additional Software Required:
WinZip or WinRAR (free versions available) for unzipping if the file is compressed.
Printability:
Printable on any computer and printer.
Zoom Capability:
Zoomable illustrations for detailed viewing.
Type:
Digital Download Only (Not a hard copy)
Note:
N/A (Digital Format)
Storage Requirement:
Manuals can be very large (up to 4000 MB), requiring sufficient storage space.
Type:
Four-stroke gasoline engine (specific displacement varies by model)
Displacement Notes:
Models include 400cc and 500cc variants. Specific engine codes (e.g., for 500cc models) would be detailed within the manual.
Horsepower Torque Notes:
Specific figures are not provided in the product description but are extensively covered within the manual.
Carburetor Type:
Likely Mikuni or Keihin carburetors, with detailed tuning and troubleshooting procedures included.
Fuel Type:
Unleaded gasoline (specified in manual, typically 87 octane or higher)
Cylinder Head Design:
Single overhead camshaft (SOHC) or similar, detailed in the manual.
Cooling Method:
Liquid-cooled
Type:
Automatic (CVT - Continuously Variable Transmission)
Type:
N/A (CVT was standard for these models)
Drive Modes:
Typically includes High, Low, Neutral, Reverse, and Park (selectable by rider).
Drive System:
Shaft-driven AWD (All-Wheel Drive) with selectable 2WD/4WD functionality is common for this generation of Sportsman.
Transmission Fluid Type:
Specific ATV transmission fluid or SAE 10W-40/20W-50 engine oil (refer to manual for exact specification and API service rating).
Notes:
Specific dimensions (length, width, height, wheelbase) vary slightly by model year and variant, and are detailed within the manual.
Dry Weight Notes:
Dry weight typically ranges from approximately 600-700 lbs depending on the specific model and configuration. Exact figures are in the manual.
Towing Capacity:
Typical towing capacity around 1,500 lbs. Specific rating detailed in the manual.
Ground Clearance Notes:
Ground clearance typically around 10-12 inches, depending on model and suspension setup. Specifics in the manual.
Notes:
No formal crash test ratings like automobiles. Safety is primarily addressed through operational guidelines and vehicle design features covered in the manual.
Braking:
Hydraulic disc brakes (front and rear), typically with hand-lever operation. Parking brake mechanism included.
Throttle Limiter:
Some models may have a throttle limiter for new riders or specific conditions, detailed in the manual.
Rollover Protection:
N/A (ATVs do not have integrated rollover protection structures like ROVs).
Lighting:
Headlights, taillight, and brake lights for visibility.
Oil Change Engine:
Typically every 100-200 operating hours or annually. Specific interval detailed in the manual.
Air Filter Cleaning:
Inspect and clean every 50 operating hours, replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement:
Recommended replacement every 1,000-2,000 miles or as per manual recommendation.
Drive Belt Inspection:
Inspect for wear and damage every 50-100 operating hours, replace as needed. Crucial for CVT function.
Engine Oil Type:
Polaris recommended synthetic or semi-synthetic 4-stroke ATV engine oil, SAE 5W-50 or 10W-40 (verify specific grade and API rating in manual).
Engine Oil Capacity:
Approximately 2.0-2.5 quarts (1.9-2.4 liters). Exact capacity in manual.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Cvt Belt Wear:
CVT belt can wear prematurely if subjected to excessive slipping, heat, or incorrect tension. Regular inspection is key.
Carburetor Issues:
Carburetors can be prone to clogging from stale fuel or debris, leading to poor running conditions. Proper fuel stabilization and cleaning are advised.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent faults. Dielectric grease is recommended for connectors.
Suspension Components:
Wear in bushings, ball joints, and tie rod ends over time due to terrain and use.
Polarismfg Co:
Polaris Industries Inc. has a long history in powersports, originating from snowmobiles and expanding into ATVs and other vehicles.
Sportsman Line:
The Sportsman line, introduced in the early 1990s, quickly became known for its comfort, utility, and independent rear suspension (IRS) which was a significant innovation for ATVs at the time.
1996-2003 Era:
This generation of Sportsman ATVs represents a period of refinement and technological advancement, including more powerful engines and improved chassis designs.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the USA (e.g., Roseau, Minnesota; Spirit Lake, Iowa).
