Polaris Sportsman Xplorer 500 400 4WD 2000 2001 2002 2003 ATV Workshop Factory Service Repair Manual

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The Polaris Sportsman Xplorer, offered in 400 4WD and 500 4WD variants, represents a robust line of All-Terrain Vehicles (ATVs) produced between 2000 and 2003. Renowned for its true 4WD...

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Type: Atv

Vendor:

Sku: 87723

Tags: 2000 2001 2002 2003 ATV Misc Polaris Powersports Sportsman Xplorer 400 Sportsman Xplorer 500

Product variants

Description

The Polaris Sportsman Xplorer, offered in 400 4WD and 500 4WD variants, represents a robust line of All-Terrain Vehicles (ATVs) produced between 2000 and 2003. Renowned for its true 4WD system, independent front suspension, and powerful engines for their class, these ATVs are engineered for versatility and reliable off-road performance. These ATVs are designed to meet ANSI/SVIA standards, offering a comfortable ride and intuitive controls suitable for a wide range of utility and recreational tasks. This comprehensive Factory Workshop Service Repair Manual provides detailed information essential for the maintenance and repair of your Polaris Sportsman Xplorer ATV. Covering all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system, this manual offers step-by-step instructions, diagnostic procedures, and precise technical specifications. With over 500 pages of factory-level detail, including exploded views and diagrams, it is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Xplorer

Model Variant:

400 4WD, 500 4WD

Model Years Covered:

2000, 2001, 2002, 2003

Codes

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Segment:

Utility ATV segment, known for versatility and off-road capability.

Competitive Analysis

Competitors:

Yamaha Grizzly, Honda Foreman/Rancher, Suzuki King Quad.

Key Features

Features:

True 4WD system, independent front suspension (IFS), powerful engines for their class, robust utility features.

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive repair and service information for Polaris Sportsman Xplorer 400/500 4WD ATVs

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Disassembly, assembly, inspection, repair, troubleshooting, specifications for both 400cc and 500cc engines.

Transmission:

PVT (Polaris Variable Transmission) system maintenance, belt inspection, clutch service, gearbox troubleshooting.

Drivetrain:

Front and rear drive components, CV joints, drive shafts, differential maintenance and repair.

Suspension:

Front and rear suspension systems, shock absorbers, A-arms, bushings, wheel bearings, alignment specifications.

Brakes:

Hydraulic brake system, calipers, master cylinder, brake lines, pad replacement, bleeding procedures, rotor specifications.

Electrical System:

Wiring diagrams, battery, starter, alternator, ignition system, lighting, diagnostics for electrical faults.

Fuel System:

Carburetor(s) (specific to engine size), fuel pump, fuel lines, fuel tank maintenance.

Cooling System:

Radiator, fan, coolant, thermostat, hoses, troubleshooting for overheating.

Chassis And Body:

Frame inspection, body panel removal and installation, seat, handle bar, rack maintenance.

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, lubrication points, spark plug service.

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Disassembly Assembly:

Complete procedures for taking apart and reassembling all vehicle systems.

Diagnostics:

Schematics, test procedures, component testing, fault code interpretation (if applicable).

Technical Depth

Depth:

Factory-level detail suitable for professional technicians and experienced DIY mechanics.

Specifications:

Torque values, clearances, fluid capacities, electrical resistance, voltage specifications.

Diagrams Illustrations:

Exploded views, detailed diagrams, wiring schematics, and step-by-step illustrations.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text content within the PDF for efficient information retrieval.

Print Quality

Quality:

High-resolution digital scans, ensuring clarity of text and images.

Binding Type

Delivery Method:

Digital Download

Paper Type

Material Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type 400:

4-stroke, liquid-cooled, SOHC, single-cylinder

Engine Displacement 400:

Approx. 375cc - 400cc (Specific variant dependent)

Engine Type 500:

4-stroke, liquid-cooled, SOHC, single-cylinder

Engine Displacement 500:

Approx. 499cc

Performance

Horsepower Estimated 400:

Approx. 20-25 HP (Varies by exact model year and tuning)

Horsepower Estimated 500:

Approx. 28-32 HP (Varies by exact model year and tuning)

Fuel System

Fuel Delivery 400:

Carburetor (e.g., Mikuni BSR32)

Fuel Delivery 500:

Carburetor (e.g., Mikuni BSR34)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Type:

Automatic (Polaris Variable Transmission - PVT)

Gearing:

High, Low, Neutral, Reverse

Features

Drive System:

Shaft drive, On-Demand True All-Wheel Drive (AWD)

📐 Dimensions

Exterior

Length:

Approx. 83-85 inches (Varies slightly by year/model)

Width:

Approx. 46-48 inches

Height:

Approx. 48-50 inches

Weights

Dry Weight 400:

Approx. 600-620 lbs

Dry Weight 500:

Approx. 620-640 lbs

Towing Capacity:

1500 lbs

Rack Capacity Front:

100 lbs

Rack Capacity Rear:

200 lbs

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI/SVIA standards.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Lighting:

Dual headlights, tail light/brake light.

Ergonomics:

Comfortable seating, ergonomic handlebars, intuitive controls.

💡 Technology Features

Infotainment

Features:

Basic functionality, focus on utility and performance rather than advanced tech. Includes analog gauges (speedometer, odometer, fuel, temp), 12V accessory outlet.

Driver Assistance

Features:

N/A (No electronic driver aids like traction control or ABS typically found on these models).

Connectivity

Features:

N/A (No modern connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100 hours or annually, whichever comes first.

Spark Plug Replacement:

Check and gap every 100 hours, replace as needed.

Air Filter Cleaning:

Check every 25-50 hours, clean or replace as needed, more frequently in dusty conditions.

Fluid Specifications

Engine Oil Type:

SAE 20W-50 API SG or higher recommended.

Engine Oil Capacity:

Approx. 2.0 - 2.3 quarts (500cc) or 1.5 - 1.8 quarts (400cc) (Refer to manual for exact)

Coolant Type:

Ethylene glycol based antifreeze (e.g., Polaris Premium Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

PVT belt wear, wheel bearings, tie rod ends, ball joints, exhaust system integrity.

Potential Failures:

Carburetor adjustment/cleaning issues, starter solenoid, occasional electrical connector corrosion.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.

Model Evolution

Lineage:

The Sportsman line is Polaris's flagship ATV range, emphasizing comfort, utility, and off-road performance.

Key Updates Era:

This generation saw refinements in chassis, suspension, and engine performance compared to earlier models.

Production

Manufacturing Location:

Primarily manufactured in the USA (Roseau, Minnesota).

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Polaris Sportsman series consistently praised for its ride comfort, capable 4WD system, and utility. Often considered a benchmark in its class.