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

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 / Xplorer 500 Year: 1996-2003 📋 Manual Details Product Information Manual Type: Digital Workshop Repair Manual Language: English Format:...

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Type: Atv

Vendor:

Sku: 28031

Tags: 1996 1997 1998 1999 2000 2001 2002 2003 ATV Misc Polaris Powersports SPORTSMAN 400 SPORTSMAN 500 XPLORER 500

Product variants

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 / 500 / Xplorer 500

Year:

1996-2003

📋 Manual Details

Product Information

Manual Type:

Digital Workshop Repair Manual

Language:

English

Format:

PDF Download

⚙️ Engine Specifications

Engine A

Engine Type:

4-stroke

Displacement:

400cc / 499cc

Cooling System:

Liquid-cooled

Bore X Stroke 400:

88mm x 64.5mm (approx)

Bore X Stroke 500:

92.3mm x 76.3mm (approx)

Carburetor Type 400:

Mikuni B24 (approx)

Carburetor Type 500:

Mikuni VM34SS (approx)

🔧 Transmission

Drivetrain

Type:

Automatic PVT (Polaris Variable Transmission)

Drive System:

2WD/4WD with On-Demand Activation

Final Drive:

Shaft Drive

📐 Dimensions

Chassis

Length:

81 inches (approx)

Width:

46 inches (approx)

Height:

47 inches (approx)

Wheelbase:

50 inches (approx)

Ground Clearance:

11.5 inches (approx)

Dry Weight:

600-650 lbs (approx)

🔧 Maintenance

Service Schedule

Engine Oil Type:

SAE 20W-50

Engine Oil Capacity:

1.7 US quarts (1.6 liters) (approx)

Coolant Type:

Ethylene Glycol Based Antifreeze

Spark Plug Gap:

0.024-0.032 inches (0.6-0.8 mm)

📄 Electrical

Ignition

Ignition System:

📄 Suspension

Front

Front Suspension Type:

Independent

Front Suspension Travel:

6.5 inches (approx)

Rear Suspension Type:

Independent

Rear Suspension Travel:

8 inches (approx)

📄 Brakes

System

Front Brake Type:

Hydraulic Disc

Rear Brake Type:

Hydraulic Disc

📄 Wheels Tires

Front

Front Tire Size:

AT25x8-12 (approx)

Rear Tire Size:

AT25x11-10 (approx)

Pressure

Tire Pressure Front:

5 psi (approx)

Tire Pressure Rear:

5 psi (approx)

📄 Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

4.0 US gallons (approx)