Model:
Sportsman 400 / Sportsman 500 / Xplorer 500
Vehicle Type:
All-Terrain Vehicle (ATV)
Product Name:
Polaris Sportsman 400 500 Xplorer 500 ATV Complete Workshop Service Repair Manual
Engine Codes:
N/A (Specific engine codes not provided in product info, refer to manual for detailed engine variants)
Chassis Codes:
N/A (Specific chassis codes not provided in product info, refer to manual for detailed model variants)
Segment:
Mid-range to high-performance utility ATVs, known for versatility and capability.
Target Audience:
Recreational riders, hunters, farmers, trail enthusiasts requiring robust and reliable ATVs.
Competitors:
Honda FourTrax, Yamaha Kodiak/Grizzly, Kawasaki Prairie/Bayou, Suzuki QuadRunner.
Features:
Independent Rear Suspension (IRS) on many models, powerful engines, comfortable seating, robust chassis, often AWD capability.
Value:
Provides comprehensive technical knowledge for maintenance, repair, and optimization of a popular range of Polaris ATVs, extending their lifespan and performance.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Included Models:
Polaris Sportsman 400, Polaris Sportsman 500, Polaris Xplorer 500
Estimated Page Count:
Likely 400-800 pages (typical for complete workshop manuals covering multiple years and models, exact count not specified)
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable PDF (implied by 'Downloadable Manual covers eve...')
Engine:
Complete overhaul, disassembly, assembly, troubleshooting, diagnosis, tuning, cooling system, lubrication system, fuel system, ignition system.
Transmission:
CVT operation, belt inspection and replacement, gearbox maintenance, lubrication, troubleshooting.
Drivetrain:
All-wheel drive system (AWD) operation, front and rear differential service, driveshaft inspection, CV joints, wheel bearings.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, bushings, lubrication, alignment procedures.
Brakes:
Hydraulic brake system, brake fluid replacement, caliper service, master cylinder, brake lines, rotor inspection, pad replacement.
Electrical:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition switch, sensors.
Fuel System:
Carburetor service and adjustment, fuel pump, fuel lines, fuel tank, fuel filter replacement.
Cooling System:
Radiator service, coolant flush and fill, fan operation, thermostat replacement.
Exhaust System:
Muffler, exhaust pipe inspection and replacement.
Body And Frame:
Frame inspection, plastic body panel removal and installation, seat, handlebars, racks.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), spark plug replacement.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement, electrical system diagnosis and repair.
Component Rebuilds:
Detailed procedures for rebuilding carburetors, fuel pumps, brake calipers, and other serviceable components.
Torque Specifications:
Essential torque values for all critical fasteners.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Detailed diagnostics and repair procedures.
Type:
Four-stroke, liquid-cooled, single-cylinder engine (typically Polaris ProStar engine architecture for this era).
Displacement Sportsman 400:
Approximately 375cc - 400cc (specific variant may vary, consult manual for exact engine codes and displacements).
Displacement Sportsman 500:
Approximately 499cc (specific variant may vary, consult manual for exact engine codes and displacements).
Displacement Xplorer 500:
Approximately 499cc (specific variant may vary, consult manual for exact engine codes and displacements).
Horsepower Sportsman 500 Approx:
Around 30-35 HP (actual figures vary by year and specific tune)
Torque Sportsman 500 Approx:
Around 28-32 lb-ft (actual figures vary by year and specific tune)
Fuel Delivery:
Carbureted (e.g., Mikuni BST, Keihin CV type carburetors are common for this era).
Fuel Type:
Unleaded gasoline (87 octane or higher recommended).
Type:
Automatic Continuously Variable Transmission (CVT) with engine braking.
Drive Modes:
High, Low, Neutral, Reverse, Park (often with selectable AWD/2WD).
Clutch Type:
Primary and secondary clutch system for CVT operation.
Transmission Fluid Spec:
Specific CVT fluid or Polaris Demand Drive fluid (refer to manual for exact specification and capacity).
Length:
Varies by model, typically around 80-85 inches (e.g., Sportsman 500 HO often around 83.2 inches).
Width:
Varies by model, typically around 46-48 inches (e.g., Sportsman 500 HO often around 46.7 inches).
Height:
Varies by model, typically around 46-50 inches (e.g., Sportsman 500 HO often around 48.2 inches).
Dry Weight:
Varies by model, typically around 550-650 lbs.
Ground Clearance:
Typically 8-11 inches, depending on model and suspension setup.
Rack Capacity Front:
Typically 50-100 lbs.
Rack Capacity Rear:
Typically 100-200 lbs.
Towing Capacity:
Typically 1,500 lbs.
Rollover Resistance:
ATVs are inherently at risk of rollovers; proper riding techniques and adherence to safety warnings are crucial. Manual will detail safety precautions.
Braking System:
Hydraulic disc brakes (front and rear), often with a single lever for front and foot lever for rear, or combined braking systems.
Aawd Engagement:
On-demand AWD systems improve traction in challenging conditions.
Lighting:
Headlights, taillight/brake light.
Seat Belt Anchorage:
N/A (ATVs typically do not use seat belts).
Display:
Basic LCD displays for odometer, trip meter, fuel level, gear indicator, clock on some models. No complex infotainment systems.
Traction Control:
While not electronic traction control, the AWD system provides significant traction assistance.
Bluetooth Usb:
N/A (Not equipped with modern connectivity features).
Ignition System:
CDI ignition system with electronic timing.
Oil Change Engine:
Typically every 100 hours or annually, whichever comes first (refer to manual for precise intervals).
Air Filter Cleaning:
Inspect every 20-40 hours, clean or replace as needed, especially in dusty conditions.
Spark Plug Replacement:
Typically every 100-200 hours or annually.
Cv Belt Inspection:
Inspect every 50-100 hours for wear and damage.
Engine Oil:
Polaris PS-4 5W-50 Synthetic (or equivalent SAE 5W-50 API SG or higher rated oil - consult manual for exact spec and capacity).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Gearcase Oil:
SAE 80W-90 Hypoid Gear Lubricant (refer to manual for specific Polaris recommended fluid and capacity).
Coolant:
Ethylene Glycol based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Common Wear Items:
CV joints/boots, suspension bushings, wheel bearings, starter solenoids, fuel pump diaphragms, brake components, CVT belts.
Carburetor Issues:
Carburetors can become clogged with fuel varnish if not used regularly or if fuel stabilizers are not used; can lead to hard starting or poor running.
Electrical Connections:
Corrosion on electrical connectors can be an issue in wet or muddy environments, requiring cleaning and dielectric grease.
Heritage:
Polaris Industries, founded in 1954, is a long-standing American manufacturer of powersports vehicles, known for innovation in snowmobiles and ATVs.
Sportsman Line:
The Sportsman line, introduced in the early 1990s, revolutionized the ATV market with features like Independent Rear Suspension (IRS) and a more comfortable, automotive-like riding position.
Xplorer Line:
The Xplorer model often represented a more utility-focused or specialized variant within the Polaris ATV lineup during this period.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Key Innovations Era:
This generation of Sportsman models solidified Polaris's reputation for rider comfort, AWD technology, and robust utility.
