🏷️ Basic Information

Make:

Polaris

Model:

Sportsman / Xplorer / Worker

Model Variants Covered:

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

Production Years Covered:

1996-2003

Manual Product Name:

POLARIS SPORTSMAN XPLORER 500 ATV ( 1996 1997 1998 1999 2000 2001 2002 2003 ) Factory Service / Repair / Maintenance Manual ( 96 97 98 99 00 01 02 03 ) - Download PDF

👋 Introduction

Target Audience:

Owners, DIY enthusiasts, and professional mechanics seeking comprehensive service information for Polaris Sportsman/Xplorer/Worker ATVs from 1996-2003.

Quality Claim:

Positions itself as the authentic factory service manual, warning against inferior or fake alternatives.

Manual Utility:

Provides everything needed to maintain, service, diagnose, and repair the vehicle with ease, eliminating the need for multiple physical manuals.

Digital Advantage:

Printable pages allow users to take only necessary information to the workshop and avoid greasy or lost paper manuals.

📋 Manual Details

Comprehensive Coverage:

All Models & All Repairs A-Z

Model Year Coverage:

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

Specific Models Covered:

1996 Sportsman 500; 1997 Sportsman 500, Xplorer 500; 1998 Sportsman 500, Worker 500; 1999 Sportsman 500, Worker 500, Sportsman 500 RSE; 2000 Sportsman 500, Worker 500, Sportsman 500 RSE, Sportsman 500 Remington Special Edition; 2001 Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 500 HO; 2002 Sportsman 400, Worker 400 (International), Sportsman 400 ASEI, Sportsman 400 DUSE, Sportsman 500 H.O., Worker 500 (International), Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom; 2003 Sportsman 400, Sportsman 500 H.O., Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400, Sportsman 400 Desert

Total Pages:

500+

Type:

Factory Service / Repair / Maintenance Manual

Language:

English

File Format:

PDF

Downloadable:

Yes

Operating Systems:

All Versions of Windows (including Vista 32/64, XP, ME, 98, NT, 2000) & Mac

Software Requirements:

Adobe PDF Reader & WinZip

📖 Manual Coverage

Engine Systems:

Engine principles, cooling, lubrication, top end (cylinder head cover, rocker assembly, camshaft, cylinder head, valves, piston, rings), lower end (flywheel, stator plate, recoil starter, crankcase, crankshaft, balancer shaft, oil pump), break-in procedures.

Fuel System:

Carburetor operation, cleaning, inspection, tests, adjustments, throttle cable replacement, stalling enrichment (choke) cable, fuel tank, fuel shutoff valve, air filter/air box, fuel pump.

Cooling System:

Polaris Variable Transmission (PVT) air cooling system, engine cooling system, safety precautions, hoses, clamps, engine gaskets/seals, cooling system inspection, radiator, cooling fan, coolant pump, thermostat, temperature sensors.

Clutch Drive Belt:

Drive unit, drive pulley, driven pulley, drive belt, clutch outer and inner cover.

Transmission Drivetrain:

Transmission inspection, shift shafts, front output shaft, transmission gearcase oil seal inspection/replacement, shift selector linkage, front drive shaft, front drive unit, Hilliard clutch.

Electrical System:

Basic information, negative battery terminal, charging system (alternator stator, voltage regulator/rectifier), capacitor discharge ignition, ignition coil, ignition stator coils, electric starting system (starter drive gears, starter solenoid), lighting system, electrical components, switches.

Suspension Steering:

Front suspension (wheel, hub, strut cartridge/spring, strut/spindle, control arm, handlebar, tie rods, steering shaft), Rear suspension (wheels, tire changing, shock absorber, hub/bearing carrier, rear axles, upper/lower control arm, stabilizer linkage/support).

Brakes:

Disc brakes, front brake pad replacement, front caliper, output shaft brake pad replacement (1996-1997 models), output shaft brake caliper (1996-1997 models), output shaft brake pad replacement (1998-on models), output shaft brake caliper (1998-on models), front master cylinder, rear master cylinder, brake hose replacement, rear brake pedal, rear brake lever (1996-1997 Sweden models), foot brake (1998-on Sweden models), brake disc, bleeding the system.

Body Chassis:

Seat, front rack and grille, side panels, front fender, front bumper, radiator guard, rear rack, rear fender, footwells, rear bumper.

Troubleshooting:

Operating requirements, troubleshooting instruments, starting the engine, starting difficulties, engine difficult to start, engine starting system issues, charging system issues, ignition system issues, electronic throttle control issues, fuel system issues, engine overheating, engine noises, cylinder leak down test, powertrain issues, steering issues, frame noise, brake issues.

Maintenance:

Pre-ride checklist, tires and wheels, battery maintenance, battery electrical cable connectors, periodic lubrication, periodic maintenance, unscheduled inspection and maintenance.

Tune Up:

Engine tune-up.

Repair Rebuild:

Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for complete repair. Includes procedures like bearing replacement, seal replacement, and complete engine disassembly/reassembly.

Diagnostics:

Diagnosis of starting difficulties, engine performance issues, electrical system faults, and more.

Depth:

Vehicle specific, factory quality, comprehensive A-Z coverage used by dealership technicians. Includes detailed instructions, diagrams, illustrations, wiring schematics, and specifications.

📊 Manual Specifications

PDF Quality:

Very High Quality, 60+ MB

Printability:

All pages are printable, allowing for enlarged copies of images and diagrams.

Searchability:

Implied by PDF format, though explicit mention of text searchability is absent. Generally, factory PDF manuals are text-searchable.

Print Quality Indicator:

High resolution for diagrams and illustrations, allowing for clarity when printed.

Binding:

Digital Download (PDF)

Paper Type Analogy:

Printable on demand on any paper type desired by the user.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 2-valve V-twin (for 500cc models); Liquid-cooled, 4-stroke, OHV, 2-valve single-cylinder (for 400cc models).

Engine Displacement:

Approx. 499cc (for 500cc models), Approx. 375cc (for 400cc models).

Horsepower Torque:

Specific figures are not provided in the product description, but the manual would contain these detailed specifications.

Fuel Delivery:

Carburetor (specific models may vary, e.g., Mikuni, Keihin). Manual covers carburetor operation, cleaning, and adjustments.

Cooling Method:

Liquid-cooled with fan assist for most models. Manual details radiator, coolant pump, and thermostat service.

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system.

Optional Transmissions:

Not applicable for this model line, standard was CVT.

Drive System:

Shaft drive to rear differential, selectable 2WD/4WD with Hilliard clutch front drive system.

Transmission Fluids:

Manual covers transmission gearcase oil seal inspection and replacement; specific fluid type and capacity would be detailed within.

📐 Dimensions

General Atv Dimensions:

Specific dimensions (L x W x H) are not provided in the product description, but would be detailed in the manual's general information section.

Dry Weight:

Dry weights varied by model and year, generally in the range of 570-650 lbs. Exact figures would be in the manual.

Payload Capacity:

Not explicitly stated, but ATVs of this era typically had rack capacities around 100 lbs front and 200 lbs rear.

Tire Sizes:

Various tire sizes were used across different models and years. Common sizes for 500cc models included 25x8-12 front and 25x10-12 rear. Manual covers tire changing and repairs.

🛡️ Safety Features

Atv Safety Standards:

Manual emphasizes 'Safety First' and handling gasoline safely, indicating adherence to general safety guidelines for ATVs.

Braking System:

Hydraulic disc brakes front and rear. Manual provides detailed brake system service information.

Warnings Labels:

Manual mentions 'Warning and information labels', suggesting factory placement of crucial safety and operational decals.

💡 Technology Features

Infotainment System:

Not applicable to these utility ATVs of the specified era; focus is on mechanical and electrical systems.

Atv Assistance Features:

The 'Electronic Throttle Control' is mentioned in the troubleshooting section, indicating some level of electronic management. Hilliard clutch is a mechanical innovation for 4WD engagement.

Connectivity Features:

Not applicable.

Ignition System:

Capacitor Discharge Ignition (CDI) system, with details on ignition coils and stator coils provided in the manual.

🔧 Maintenance

General Maintenance Schedule:

Manual includes 'Periodic Lubrication', 'Periodic Maintenance', and 'Engine Tune-up' sections, indicating scheduled service points (e.g., pre-ride checks, oil changes, filter replacements) that would be detailed with specific intervals.

Engine Oil:

Specific oil type (e.g., SAE 10W-40 or 20W-50) and capacity would be detailed within the lubrication and tune-up chapters.

Coolant Type:

Manual covers engine cooling system and coolant pump; specific coolant type (e.g., ethylene glycol-based) and capacity would be specified.

Brake Fluid:

Manual covers brake systems and bleeding; specific brake fluid type (e.g., DOT 3 or DOT 4) would be specified.

Gearcase Oil:

Manual details transmission gearcase oil seal inspection; specific oil type and capacity for the transmission/gearcase would be listed.

Common Wear Items:

Given the age range, common wear items would include drive belts, brake pads, wheel bearings, ball joints, tie rod ends, and suspension bushings. The manual addresses maintenance and replacement of these.

Engine Performance Issues:

Manual's troubleshooting section covers starting difficulties, engine noises, and overheating, indicating common potential problems addressed by the documentation.

Spark Plug:

Specific spark plug type, gap, and replacement interval would be detailed in the engine tune-up section.

Air Filter:

Manual covers air filter/air box; replacement or cleaning intervals and specific part numbers would be listed.

📚 Vehicle History

Polaris Atv Legacy:

Polaris is a long-standing manufacturer of ATVs, known for innovation in the off-road vehicle market. The Sportsman line has been a flagship model.

Sportsman Development:

The Sportsman 500 was introduced in the mid-90s and quickly became a popular utility ATV, evolving with engine upgrades (H.O.), special editions (RSE, DUSE), and chassis refinements over the years covered.

Manufacturing Origin:

Primarily manufactured in the United States by Polaris Industries.

🏆 Awards & Recognition

Atv Industry Awards:

Specific awards for these model years are not detailed in the product description, but the Polaris Sportsman line has historically received positive reviews and industry recognition for its utility and performance.