Polaris Sportsman Xplorer Worker 400 500 ATV All Terrain Vehicle Complete Workshop Service Repair Manual 1996 1997 1998 1999 2000 2001 2002 2003

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Type: Atv

Vendor:

Sku: 78918

Tags: 1996 1997 1998 1999 2000 2001 2002 2003 ATV Misc Polaris Powersports Sportsman Worker 400 Worker 500 Xplorer

Product variants

Description

The Sportsman Xplorer Worker, available in 400 and 500 model variants, represents a robust utility All-Terrain Vehicle (ATV) designed for professional users, landowners, hunters, and recreational riders who demand reliable performance and substantial hauling capabilities. Produced between 1996 and 2003, these ATVs are distinguished by their focus on work, featuring strong towing and cargo capacity, and a durable construction built for rugged use across diverse terrains. Engineered with a strong emphasis on utility, the Sportsman Xplorer Worker series offers dependable operation, making it a capable partner for demanding tasks and challenging environments. This comprehensive workshop service repair manual, written in English, provides detailed guidance for the maintenance and repair of the Sportsman Xplorer Worker models from 1996 to 2003. It covers all essential systems, including the engine, powertrain, chassis, electrical, and fuel systems, offering in-depth procedures for regular maintenance, component overhauls, and troubleshooting. With clear instructions, technical specifications, and detailed illustrations, this manual serves as an invaluable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Xplorer Worker

Model Variant:

400, 500

Codes

Vin Prefix:

4XTC (Polaris ATV)

👋 Introduction

Market Position

Segment:

Utility ATV (All Terrain Vehicle)

Target User:

Professional users, landowners, hunters, recreational riders requiring robust performance and utility

Competitive Analysis

Competitors:

Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou, Suzuki King Quad

Key Features

Utility Focus:

Emphasis on work capability, towing, hauling, and reliable operation in diverse terrains

Durability:

Designed for rugged use and extended operational life

📋 Manual Details

Coverage Areas

Years Covered:

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

Page Count

Estimated Page Count:

Approx. 300-500 pages (typical for this era and scope)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Drive Systems (AWD/2WD), Differentials, Drive Shafts, CV Joints

Chassis:

Frame, Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Wheels, Tires

Electrical:

Ignition System, Charging System (Stator, Rectifier/Regulator, Battery), Starting System (Starter Motor, Solenoid), Lighting, Instruments, Wiring Diagrams, Switches, Controls

Fuel System:

Carburetor(s) (Maintenance, Adjustment, Rebuild), Fuel Pump, Fuel Lines, Fuel Tank

Cooling System:

Radiator, Fan, Hoses, Thermostat, Coolant

Exhaust System:

Exhaust Pipes, Muffler, Heat Shields

Body And Trim:

Body Panels, Fenders, Racks, Seat, Handlebars, Decals

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, lubrication points, battery care, tire pressure checks

Repair:

Engine overhaul, transmission repair, carburetor rebuild, brake system service, suspension component replacement, electrical component troubleshooting and repair

Troubleshooting:

Diagnostic charts for common problems (starting issues, poor performance, electrical faults, etc.)

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters

Diagrams:

Detailed exploded views, wiring diagrams, service illustrations

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and component rebuilds)

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable text, printable pages

Print Quality

Printability:

Designed for clear printing of text and diagrams

Binding Type

Binding For Download:

N/A (Digital PDF)

Paper Type

Paper Type For Download:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type 400:

4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder

Engine Type 500:

4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder

Displacement

Displacement 400:

Approximately 375cc - 400cc (exact varies by specific sub-model/year)

Displacement 500:

Approximately 499cc - 500cc (exact varies by specific sub-model/year)

Performance

Horsepower 400:

Estimated 20-25 HP (varies by year/tuning)

Horsepower 500:

Estimated 28-32 HP (varies by year/tuning)

Torque 400:

Estimated 22-25 lb-ft (varies by year/tuning)

Torque 500:

Estimated 28-32 lb-ft (varies by year/tuning)

Fuel System

Carburetor Type:

Mikuni or Keihin Single Carburetor (specific model dependent)

Fuel Type:

Unleaded Gasoline

Lubrication

Oil Type:

SAE 20W-50 or 10W-40 Motorcycle/ATV Oil (refer to manual for exact specification)

Cooling System

Coolant Type:

Ethylene Glycol-based Antifreeze (50/50 mix with distilled water recommended)

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission) with Hi/Lo Range and Reverse

Optional

Optional Transmission Types:

N/A (CVT was standard across these models)

Features

Drive Selection:

On-Demand All-Wheel Drive (AWD) / 2WD selectable

Final Drive:

Shaft Drive (to rear differential and front wheels)

Fluid Specifications

Transmission Fluid Type:

Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent (check manual for specific part number)

📐 Dimensions

Exterior

Length:

Approx. 80-85 inches (203-216 cm)

Width:

Approx. 45-48 inches (114-122 cm)

Height:

Approx. 46-48 inches (117-122 cm)

Weights

Dry Weight:

Approx. 550-600 lbs (249-272 kg)

Ground Clearance:

Approx. 8-11 inches (20-28 cm)

Cargo

Rack Capacity Front:

Approx. 90 lbs (40 kg)

Rack Capacity Rear:

Approx. 200 lbs (90 kg)

Towing Capacity:

Approx. 1,225 - 1,500 lbs (556 - 680 kg)

Tires

Front Tire Size:

25x8-12 or 26x8-12 (typical)

Rear Tire Size:

25x11-12 or 26x11-12 (typical)

Tire Pressure Front:

Typically 5-7 PSI (refer to manual for exact specs)

Tire Pressure Rear:

Typically 5-7 PSI (refer to manual for exact specs)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Compliant with ANSI/SVIA standards (where applicable for the era)

Active Features

Braking System:

Hydraulic Disc Brakes (Front and Rear)

Parking Brake:

Integrated into rear caliper or separate mechanism

Passive Features

Lighting:

Headlights, Taillight, Brake Light

Operator Controls:

Handlebar steering, throttle, brake levers, gear selector

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, odometer, tachometer, fuel gauge, coolant temperature warning light, AWD indicator, gear indicator (PRNDL).

Driver Assistance

Atv Assistance:

On-demand AWD system enhances traction and stability.

Connectivity

Vehicle Connectivity:

N/A (No modern electronic connectivity features)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 100 hours or annually (whichever comes first)

Air Filter Cleaning:

Inspect every 20 hours, clean or replace as needed. Service more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 100-200 hours or annually.

Drive Belt Inspection:

Inspect regularly for wear and damage, replace as needed (typical replacement interval 1000-2000 hours, but inspection is key).

Fluid Specifications

Engine Oil Capacity:

Approximately 2.0 - 2.5 quarts (1.9 - 2.4 liters) - refer to manual for exact capacity

Coolant Capacity:

Approximately 1.5 - 2.0 quarts (1.4 - 1.9 liters) - refer to manual for exact capacity

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid

Known Issues

Cvt Belt Wear:

CVT belt wear or slippage can occur with heavy use or improper maintenance.

Carburetor Tuning:

Carburetors may require periodic cleaning and tuning, especially if the vehicle sits for extended periods.

Electrical Connections:

Corrosion or looseness in electrical connections can lead to intermittent issues.

📚 Vehicle History

Brand Heritage

Polar Heritage:

Polaris has a long history of producing off-road vehicles, including ATVs, snowmobiles, and UTVs, known for innovation and ruggedness.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from basic utility models to feature-rich recreational and work-oriented machines.

Xplorer Worker Positioning:

These models combined the ruggedness of the Explorer series with the 'Worker' designation emphasizing enhanced utility and towing capabilities, targeting agricultural, ranching, and heavy-duty recreational use.

Production

Manufacturing Location:

Primarily manufactured in the United States by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Atv Market Impact:

Polaris Sportsman models of this era were highly regarded for their robust design, utility, and four-wheel-drive capabilities, establishing Polaris as a major player in the utility ATV market.