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POLARIS SPORTSMAN XPLORER 400 500 4X4 Digital Workshop Repair Manual 1996-2003

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$16.99
🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer Sub Model: 400, 500 4x4 Year Range: 1996-2003 Codes Chassis Code: AWD 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) /...
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Type: Atv
Vendor:
Polaris
Sku: 28290
Tags: 1996 1997 1998 1999 2000 2001 2002 2003 400 4X4 500 ATV Misc Polaris Powersports SPORTSMAN XPLORER
POLARIS SPORTSMAN XPLORER 400 500 4X4 Digital Workshop Repair Manual 1996-2003
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman Xplorer
Sub Model:
400, 500 4x4
Year Range:
1996-2003
Codes
Chassis Code:
AWD
👋 Introduction
Market Position
Category:
All-Terrain Vehicle (ATV) / Utility Vehicle
Target User:
Owners, mechanics, enthusiasts focused on maintenance, repair, and restoration
Competitive Analysis
Competitors:
Honda FourTrax, Yamaha Kodiak, Suzuki King Quad, Kawasaki Prairie
Key Features
Vehicle Focus:
Ruggedness, 4x4 capability, utility for work and recreation
Manual Value:
Empowers owners to perform their own maintenance and repairs, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Manual Type:
Digital Workshop Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Extensive (Exact number not provided, but implied to be comprehensive)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnosis, tuning, cooling system, lubrication system, fuel system, ignition system, exhaust system
Transmission:
Automatic transmission operation, disassembly, inspection, reassembly, fluid service, troubleshooting
Drivetrain:
4x4 system, CV joints, driveshafts, differentials, hubs, bearing replacement
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment procedures
Brakes:
Hydraulic system, brake calipers, brake pads, rotors, master cylinder, bleeding procedures, parking brake
Steering:
Steering column, tie rods, steering rack/box, power steering system (if applicable), linkage
Electrical:
Wiring diagrams, battery, starting system, charging system, lighting, ignition switch, fuses, relays, diagnostic codes
Bodywork:
Body panels, fenders, rack systems, seat removal/installation, plastics, decals
Cooling:
Radiator, fan, coolant types, hoses, thermostat, water pump
Fuel:
Carburetor specifications, fuel pump, fuel lines, fuel tank, fuel filter
Procedures Included
Maintenance:
Regular service intervals, oil changes, filter replacement, lubrication points, valve adjustments (if applicable)
Troubleshooting:
Diagnostic charts, symptom-based problem solving, common failures and remedies
Repair:
Step-by-step instructions for component removal, rebuilding, and installation
Rebuild:
Detailed instructions for engine and transmission rebuilds
Restoration:
Guidance on refurbishing and restoring older models
Technical Depth
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text within PDF
Printability:
Printable
Print Quality
Image Clarity:
High-quality images and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, liquid-cooled, SOHC, 4-valve
Displacement 400:
375cc (approx.)
Displacement 500:
499cc (approx.)
Performance
Horsepower Approx:
30-35 HP (Varies by model and year)
Torque Approx:
30-35 lb-ft (Varies by model and year)
Fuel System
Carburetor:
Mikuni (Specific model may vary by year)
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Cooling
Cooling System:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse
Features
Clutch System:
Centrifugal clutch with drive and driven pulleys
Fluid Specifications
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 10W-30 API SG or higher
📐 Dimensions
Exterior
Length Approx:
81-83 inches
Width Approx:
46-48 inches
Height Approx:
47-49 inches
Weights
Dry Weight Approx:
550-600 lbs
Towing Capacity:
1500 lbs (approx.)
Rack Capacity Front:
100 lbs (approx.)
Rack Capacity Rear:
200 lbs (approx.)
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet ANSI/SVIA standards for recreational vehicles
Active Features
Braking System:
Hydraulic disc brakes front and rear
Parking Brake:
Hand-operated lever engaging rear brakes
Passive Features
Lighting:
Headlights, taillight, brake light
Seat Belt Recommendation:
Not standard, but recommended for responsible operation
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation: speedometer, odometer, trip meter, neutral light, oil light, temperature warning light.
Driver Assistance
Features:
N/A (Focus on mechanical and electrical systems for repair)
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or annually (refer to manual for exact intervals)
Air Filter Cleaning:
Inspect every 25 hours, clean/replace as needed
Spark Plug Replacement:
Refer to manual for recommended interval
Fluid Specifications
Engine Oil Type:
SAE 10W-30 API SG or higher (Polaris brand recommended)
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (refer to manual)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Drive belt, starter motor, ball joints, tie rod ends, wheel bearings
Carburetor Tuning:
Can require periodic adjustment or cleaning due to fuel variability and usage conditions.
Cv Boot Failure:
Susceptible to tears from debris, requiring timely replacement to prevent joint damage.
Cooling System Maintenance:
Regular flushing and correct coolant level are critical to prevent overheating.
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries
Brand Reputation:
Pioneer in the powersports industry, known for innovation in ATVs.
Model Evolution
Xplorer Lineage:
The Xplorer line was designed for more extended trail riding and utility compared to the sportier Sportsman models.
Production
Production Period:
1996-2003
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Polaris consistently received industry accolades for its ATV innovations and market leadership during this period.
Ratings
Customer Satisfaction:
Generally high, with the Sportsman line being a best-seller, though specific ratings vary by year and model.
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