🏷️ Basic Information

Make:

Polaris

Model:

Sportsman, Xplorer, Worker

Engine Options:

400cc, 500cc

Years Covered:

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

Platform Code:

AWD/4x4 ATV Platform

👋 Introduction

Positioning:

The Polaris Sportsman series, introduced in the mid-1990s, quickly established itself as a dominant force in the utility ATV market, renowned for its ruggedness, versatility, and rider comfort. This manual addresses a critical period in its development, covering the popular 400 and 500cc models.

Competitors:

During this era, key competitors included Can-Am Outlander, Yamaha Kodiak, Honda Foreman, and Kawasaki Prairie. The Sportsman series often differentiated itself with its independent rear suspension (IRS) and a focus on rider ergonomics.

Manual Value:

Provides authoritative guidance for maintaining and repairing a wide range of Polaris ATVs, empowering owners to perform tasks themselves, save on service costs, and ensure longevity of their vehicles.

📋 Manual Details

Specific Models Covered:

Sportsman 400, Sportsman 500, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 500 HO, Sportsman 400 ASEI, Sportsman 400 DUSE, 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), Worker 400, Worker 500, Xplorer 500 (all model years 1996-2003)

Estimated Pages:

500+

Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

All Major Systems:

Engine mechanical, Fuel system, Ignition system, Cooling system, Lubrication system, Drivetrain, Transmission, Clutch, Driveshafts, Axles, Suspension (front and rear), Steering, Brakes (hydraulic and parking), Electrical system (charging, starting, lighting, ignition, accessories), Chassis, Frame, Bodywork, Wheels and tires, Specialized ATV systems (e.g., AWD engagement, differential systems)

Repair And Maintenance:

Routine maintenance schedules, Troubleshooting guides, Component disassembly and reassembly, Engine overhaul, Transmission repair, Carburetor tuning and rebuilding, Electrical diagnostics and repair, Suspension and steering adjustments, Brake system servicing, Body panel repair and replacement, Clutch adjustments and replacement, Drive belt inspection and replacement, Special tool requirements and usage

Depth Of Coverage:

Comprehensive, covering everything from basic tune-ups and fluid changes to complete engine rebuilds and advanced diagnostic procedures. Suitable for both novice DIY mechanics and experienced technicians.

📊 Manual Specifications

File Type:

Searchable PDF

Image Resolution:

High-resolution for clear diagrams and text

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

4-stroke, Liquid-Cooled, Single-Cylinder (500cc models); 4-stroke, Liquid-Cooled, Single-Cylinder (400cc models)

Displacement 500:

499cc

Displacement 400:

375cc (approximate)

Bore X Stroke 500:

93.2 mm x 72.2 mm (typical for 500cc models)

Compression Ratio 500:

9.5:1 (typical)

Horsepower 500:

Approx. 30-35 HP (depending on specific model and year)

Torque 500:

Approx. 29-32 lb-ft (depending on specific model and year)

Carburetor 500:

Mikuni BSR42 (typical for 500cc models)

Carburetor 400:

Various Mikuni models (e.g., BSR32 for 400cc models)

🔧 Transmission

Type:

Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse

Options:

N/A (Automatic PVT was standard across these models)

Drive System:

Shaft Drive to Front and Rear Wheels, with On-Demand AWD engagement

Final Drive Type:

Gear Reduction

📐 Dimensions

Length:

Approx. 81-83 inches (varies by model)

Width:

Approx. 46-48 inches (varies by model)

Height:

Approx. 48-50 inches (varies by model)

Dry Weight:

Approx. 550-600 lbs (varies by model)

Ground Clearance:

Approx. 10-11 inches (varies by model)

Towing Capacity:

Approx. 1500 lbs

Rack Capacity Front:

Approx. 90 lbs

Rack Capacity Rear:

Approx. 150-200 lbs (varies by model)

🛡️ Safety Features

Atv Safety Standards:

Designed to meet applicable ANSI safety standards for ATVs.

Braking System:

Hydraulic disc brakes (front and rear), often with single-lever control for front and foot control for rear. Parking brake.

All Wheel Drive:

On-Demand All-Wheel Drive (AWD) system for enhanced traction.

Lighting:

Headlights, taillight, brake light.

Ergonomics:

Designed for rider comfort and control, contributing to overall safety.

💡 Technology Features

Features:

Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems were standard on these utility ATVs.

Features:

On-Demand AWD is a key traction management technology. No electronic driver aids like ABS or traction control were common.

Features:

N/A

🔧 Maintenance

Oil Change:

Every 100 hours or 6 months (typically, refer to manual for exact interval and specific model)

Air Filter Cleaning:

As needed, or every 25-50 hours (depending on operating conditions)

Spark Plug Replacement:

Every 100 hours or annually (typical)

Engine Oil Type:

SAE 20W-40 Motorcycle/ATV specific oil (refer to manual for precise API service classification and viscosity)

Engine Oil Capacity 500:

Approx. 2.2-2.5 quarts (with filter change, verify in manual)

Transmission Fluid Type:

Polaris Synthetic Gearcase Lubricant or equivalent SAE 80W-90 GL-4 gear oil (verify in manual)

Coolant Type:

Ethylene Glycol based antifreeze/coolant (50/50 mix with distilled water)

Common Wear Items:

Drive belt wear, carburetor adjustments due to ethanol fuels, cooling system component aging, battery health, potential for front differential issues if abused or improperly maintained.

Maintenance Focus:

Regular inspection and replacement of the drive belt are critical for the PVT system. Proper cooling system maintenance prevents overheating, especially in demanding conditions.

📚 Vehicle History

Polaristrack Record:

Polaris Industries has a long-standing reputation for innovation and performance in the powersports industry, particularly in the ATV segment since its early days.

Sportsman Lineage:

The Sportsman line represented Polaris' commitment to a comfortable, capable, and user-friendly utility ATV. The 400 and 500cc models were foundational to the brand's success in this category.

Key Innovations:

Introduction of Independent Rear Suspension (IRS) on many models, which significantly improved ride quality and handling compared to solid-axle designs prevalent at the time.

Manufacturing Location:

Primarily manufactured in the United States by Polaris Industries.

🏆 Awards & Recognition

Industry Acclaim:

Polaris Sportsman models from this period were widely praised for their utility, comfort, and all-around capability, often receiving positive reviews from ATV publications and earning strong market sales.