Target audience:
Utility ATV buyers needing a work-and-trail machine for farm, ranch, and hunting use
Segment:
Mid-displacement 4x4 utility ATV
Primary competitors:
Honda FourTrax 300, Kawasaki Bayou 400, Yamaha Big Bear 350
Competitive advantage:
On-Demand all-wheel drive and independent rear suspension were ahead of most rivals of the era
Key features:
Single-cylinder liquid-cooled 500 engine, On-Demand 4WD, independent rear suspension, automatic CVT-style transmission
Manual type:
Factory-style workshop repair manual
Coverage areas:
Engine, drivetrain, chassis, electrical, fuel, and body systems
Delivery method:
Instant digital download
Binding:
Digital (PDF document)
Compatibility:
Viewable on computer, tablet, and smartphone
Engine:
Complete removal, disassembly, inspection, rebuild, and reassembly procedures
Fuel system:
Carburetor servicing, fuel pump, tank, and lines
Cooling system:
Radiator, coolant flow, thermostat, and fan testing
Lubrication:
Oil change and lubrication specifications
Exhaust system:
Muffler, header pipe, and mounting procedures
Clutch / drive system:
Drive and driven clutch (PVT) inspection, cleaning, and service
Transmission / gearbox:
Gearcase service, shifting linkage, and final drive
Front and rear suspension:
A-arm, strut, shock, and swing arm service and alignment
Steering:
Steering assembly inspection and adjustment
Brakes:
Front and rear hydraulic brake service, pad replacement, bleeding
Wheels and tires:
Tire pressure, wheel removal, and hub service
Electrical system:
Wiring diagrams, battery, charging system, CDI ignition, starter
Lighting and instruments:
Headlight, taillight, switch, and gauge diagnosis
Body and frame:
Fender, rack, and frame component procedures
General maintenance:
Periodic lubrication, torque specs, and tune-up intervals
Procedures included:
Step-by-step repair, overhaul, and maintenance procedures with torque values
Diagnosis content:
Troubleshooting charts for engine, electrical, and drivetrain faults
Specifications:
Full torque tables, fluid capacities, and fastener specs
Technical depth:
Written for professional technicians, usable by experienced DIY owners
Special tools:
Identifies required and recommended special tools
Parts data:
OEM part numbers and exploded views for ordering replacement parts
Exploded diagrams:
Component breakdown illustrations throughout the manual
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Primary engine:
483cc single-cylinder four-stroke, liquid-cooled
Engine options range:
One engine offered across 1996-1998 (483cc single)
Bore and stroke:
83mm x 89mm
Valvetrain:
SOHC, 4-valve head
Compression ratio:
Approximately 9.0:1
Fuel system:
Mikuni BST-34 carburetor
Ignition:
Solid-state CDI electronic ignition
Starting system:
Electric start with recoil backup
Cooling:
Liquid-cooled with radiator and electric fan
Standard transmission:
5-speed constant-mesh gearbox with automatic clutch, Hi-Lo range, reverse
Final drive:
Shaft drive to all four wheels
Drive mode:
On-Demand 4WD with true AWD engagement, 2WD selectable
Drive clutch:
Polysynchronous Variable Transmission (PVT) automatic clutch system
Transmission features:
Engine braking through gearbox, neutral and reverse operation
Wheelbase:
Approximately 50.5 inches (1283mm)
Length:
Approximately 81 inches (2057mm)
Width:
Approximately 46 inches (1168mm)
Curb weight:
Approximately 700 lb (318 kg)
Ground clearance:
Approximately 10.5 inches
Fuel capacity:
Approximately 4.5 gallons
Crash test rating:
N/A - ATVs are not crash tested by NHTSA or IIHS
Braking system:
Dual front hydraulic disc brakes, single rear hydraulic disc brake
Active safety:
On-Demand 4WD for traction; engine braking in Hi-Lo ranges
Passive safety:
Front and rear storage racks, standard footrests
Operator requirements:
Helmet and eye protection recommended; not intended for riders under 16
Engine oil:
Change every 100 hours of operation or annually, whichever comes first
Air filter:
Inspect before each ride; replace as needed, more often in dusty conditions
Gearcase oil:
Change annually or per interval table
Valve clearance:
Check and adjust per scheduled interval
Coolant:
Inspect level regularly; replace per interval schedule
Engine oil type:
Premium 4-stroke API SF/SG oil; viscosity per climate chart in manual
Gearcase oil:
Polaris gearcase lubricant or equivalent
Coolant:
50/50 ethylene glycol antifreeze and distilled water
Brake fluid:
DOT 3 hydraulic brake fluid
Common wear items:
Drive belt, brake pads, CV boots, and clutch components
PVT system note:
Keep drive clutch housing clear of water and debris to prevent belt slippage
Manufacturer:
Polaris Industries, founded 1954 in Roseau, Minnesota
Model evolution:
The Xplorer line was Polaris's trail-oriented utility ATV; the 500 Xplorer brought the 483cc liquid-cooled single with On-Demand 4WD and independent rear suspension to the mid-1990s lineup
Production location:
United States (Polaris Minnesota facilities)
Era significance:
Mid-1990s models helped establish Polaris as a leader in independent rear suspension 4x4 ATVs
