🏷️ Basic Information

Make:

Polaris

Model:

Sportsman, Xplorer, Worker

Model Variants:

Sportsman 500, Sportsman 400, Xplorer 500, Worker 500, Worker 400, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 400 ASEI, 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

Model Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Product Id:

Not Specified

👋 Introduction

Target Audience:

Do-It-Yourself (DIY) owners and independent repair shops.

Value Proposition:

Provides essential repair information for immediate repairs, saving money and ensuring proper maintenance.

Completeness:

Most complete service repair manual available for the specified models.

Ease Of Use:

Easy-to-follow, step-by-step instructions suitable for all skill levels.

Customer Satisfaction:

Customer Satisfaction Always Guaranteed

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Page Count:

Not Specified (Downloadable PDF)

File Format:

PDF

Compatibility:

All Versions of Windows & Mac

Readability Requirements:

Adobe PDF Reader

Printability:

All pages printable

📖 Manual Coverage

General Information:

Included

Troubleshooting:

Included

Lubrication Maintenance Tune Up:

Included

Engine Top End:

Included

Engine Lower End:

Included

Fuel System:

Included (Carburetion)

Cooling Systems:

Included

Clutch Drive Belt System:

Included (Clutching)

Transmission:

Included

Front Drive System:

Included (Final Drive)

Electrical System:

Included (Wiring Diagrams)

Front Suspension Steering:

Included (Body and Steering)

Rear Suspension:

Included

Brakes:

Included

Body:

Included

Specific Year Info:

2001-2003 Service Information

Maintenance:

Comprehensive (Lubrication, Tune-up, Fluid Changes, Filter Replacements)

Repair:

Detailed step-by-step repair procedures for all covered systems.

Diagnostics:

Troubleshooting guides for identifying and resolving common and uncommon issues.

Assembly Disassembly:

Complete instructions for component removal and installation.

Depth:

Advanced diagnostics and repair procedures suitable for DIY enthusiasts and professional technicians.

Documentation Quality:

Comprehensive details, diagrams, and pictures for clarity.

📊 Manual Specifications

File Type:

Digital Download (PDF)

Print Capability:

High-resolution, fully printable pages.

Binding:

N/A (Digital)

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Engine Type:

Four-stroke, Single-cylinder (typically Polaris Pro Series Engine)

Displacement 500Cc Models:

Approximately 499cc

Displacement 400Cc Models:

Approximately 375cc (specific variants may differ)

Horsepower 500Cc:

Varies by year and model, generally in the range of 30-34 HP (H.O. models may have higher output).

Torque 500Cc:

Varies by year and model, typically around 26-30 lb-ft.

Fuel Delivery:

Carbureted (e.g., Mikuni, Keihin) for most models; some later H.O. models may feature fuel injection.

Fuel Type:

Unleaded Gasoline (Octane rating as specified in manual)

Cooling Method:

Liquid-cooled

Oil Type:

Specific synthetic or semi-synthetic ATV engine oil meeting Polaris specifications (e.g., SAE 0W-40, 10W-40, 20W-50 depending on temperature).

🔧 Transmission

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with engine braking.

Gear Selection:

High, Low, Neutral, Reverse, Park.

Drive System:

Shaft Drive, On-Demand AWD (All-Wheel Drive) for most models, 2WD/AWD selectable.

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent.

📐 Dimensions

Wheelbase:

Approximately 50.5 inches (Varies slightly by model).

Ground Clearance:

Approximately 10.5 inches (Varies by model).

Dry Weight:

Approximately 600-650 lbs (Varies by model).

🛡️ Safety Features

Atv Safety:

ATVs are inherently off-road vehicles and require proper safety gear and training. Manual emphasizes safe operation.

Braking System:

Hydraulic disc brakes (front and rear).

Lighting:

Headlights, Taillight/Brake Light.

💡 Technology Features

Dashboard Features:

Basic digital/analog gauges (speedometer, odometer, trip meter, fuel gauge, tachometer), indicator lights (neutral, reverse, AWD, etc.).

Atv Systems:

On-demand AWD system, engine braking on deceleration.

Diagnostic Ports:

Diagnostic connectors for service tools (covered in manual).

🔧 Maintenance

Oil Change:

Typically every 50-100 operating hours or annually, whichever comes first. Refer to manual for exact intervals.

Air Filter:

Regular inspection and cleaning/replacement based on operating conditions (e.g., dusty environments).

Spark Plug:

Recommended replacement at specified intervals (e.g., every 100-200 operating hours).

Coolant Type:

Polaris Premium 2-Stroke Synthetic Oil (for mixing with fuel for the 2-stroke models) or Ethylene Glycol based coolant for liquid-cooled 4-strokes.

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Common Wear Items:

Drive belts, wheel bearings, ball joints, tie rod ends, brake pads.

Potential Problems:

Carburetor adjustments/cleaning, PVT system maintenance (clutch inspection/cleaning), electrical connections, potential for overheating if cooling system is not maintained.

📚 Vehicle History

Polaris Atv Legacy:

Polaris pioneered the modern ATV industry, known for innovation and ruggedness.

Sportsman Lineage:

The Sportsman line has been a flagship for Polaris, evolving into one of the most popular utility ATVs.

Manufacturing Location:

Polaris Industries Inc. facilities in the USA.

🏆 Awards & Recognition

Industry Standing:

Polaris Sportsman series is consistently recognized for its utility, versatility, and off-road capability.