Model:
Sportsman Xplorer Worker
Product Type:
Service Repair Shop Manual Download
Covered Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Target Audience:
Recreational riders, hunters, ranchers, and general utility users seeking robust and reliable off-road capability.
Competitors Era:
Competed with models from Honda (FourTrax), Yamaha (Grizzly/Kodiak), Kawasaki (Bayou/Prairie), Suzuki (KingQuad), Arctic Cat (ATVs).
Platform Strengths:
Renowned for ruggedness, versatility, and Polaris's signature AWD system (On-Demand All-Wheel Drive), comfortable seating, and cargo hauling capacity.
Primary Coverage:
Polaris Sportsman Xplorer Worker 400 and 500 ATVs
Secondary Coverage:
All Terrain Vehicle (ATV) specific maintenance and repair
Estimated Pages:
Varies by specific model and engine, typically 300-600 pages for comprehensive service manuals
Type:
Service and Repair Manual
Purpose:
In-depth technical guidance for maintenance, troubleshooting, and repair
Device Compatibility:
PC, MAC, Tablets, Smartphones
Engine Systems:
Engine overhaul, top-end rebuild, bottom-end components, cooling system, lubrication, fuel system, ignition system, starting system, exhaust system
Drivetrain Systems:
Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, chain drive, final drive, gearbox, differential (if applicable)
Chassis And Suspension:
Frame, front suspension (MacPherson strut, A-arms), rear suspension (swingarm, shock absorbers), steering system, wheel bearings, tires
Electrical Systems:
Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), starter motor, instrumentation, accessories
Braking Systems:
Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, parking brake
Body And Trim:
Body panels, fenders, racks, seating, controls, decals
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug inspection/replacement, fluid level checks, lubrication points, battery maintenance, air filter cleaning/replacement
Repair Procedures:
Engine component replacement (pistons, rings, valves), transmission service, suspension component repair, brake system bleeding and component replacement, electrical troubleshooting and component repair
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting charts, electrical diagnostic guides
Special Tools:
Identification and use of specialized tools required for specific procedures
Depth:
Comprehensive, covering from basic user maintenance to advanced mechanical and electrical repairs, suitable for professional technicians and experienced DIY enthusiasts.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and troubleshooting trees for identifying and resolving malfunctions.
Searchability:
Typically fully searchable text for quick information retrieval.
Quality:
High-resolution, designed for clear viewing and printing of diagrams and text.
Binding:
Not Applicable (Downloadable PDF)
Paper:
Not Applicable (Digital Format)
Engine Type:
4-stroke, SOHC, air-cooled or liquid-cooled (depending on specific sub-model)
Displacement:
Approximately 375-400cc (actual displacement varies by year and specific 400 model)
Bore X Stroke:
Refer to specific model year for exact figures
Compression Ratio:
Refer to specific model year for exact figures
Engine Type:
4-stroke, SOHC, liquid-cooled
Displacement:
Approximately 499cc (actual displacement varies by year and specific 500 model)
Bore X Stroke:
Refer to specific model year for exact figures
Compression Ratio:
Refer to specific model year for exact figures
Horsepower 400:
Estimated 20-25 HP (varies by specific model)
Horsepower 500:
Estimated 28-32 HP (varies by specific model)
Torque:
Refer to specific model year for exact figures
Fuel Delivery 400:
Carburetor (e.g., Mikuni BST series, Keihin)
Fuel Delivery 500:
Carburetor (e.g., Mikuni BST series, Keihin), some later models may feature fuel injection
Fuel Type:
Unleaded gasoline (87 octane minimum recommended)
Type:
Polaris Variable Transmission (PVT) with Automatic CVT (Continuously Variable Transmission)
Drive Modes:
2WD, 4WD (On-Demand All-Wheel Drive)
Gear Selection:
High, Low, Neutral, Reverse
Clutch System:
Dual centrifugal clutch system (drive clutch and driven clutch)
Length:
Approx. 82-85 inches (varies by specific model)
Width:
Approx. 46-48 inches (varies by specific model)
Height:
Approx. 48-50 inches (varies by specific model)
Dry Weight:
Approx. 550-600 lbs (varies by specific model)
Ground Clearance:
Approx. 10-11 inches (varies by specific model)
Towing Capacity:
Typically 1200-1500 lbs (check specific model for exact rating)
Payload Capacity:
Typically 250-300 lbs (check specific model for exact rating)
Rack Capacity Front:
Approx. 100 lbs
Rack Capacity Rear:
Approx. 200 lbs
Atv Safety Standards:
Adheres to ANSI and industry safety standards for ATVs.
Braking System:
Hydraulic disc brakes, front and rear. Parking brake mechanism.
Suspension Stability:
Independent front suspension and rear suspension contribute to stability and control over varied terrain.
Rollover Protection:
No integrated rollover protection system (ROPS) as standard; rider caution and appropriate protective gear are essential.
Lighting:
Dual headlights, brake light, taillight for visibility.
Instrumentation:
Digital odometer, speedometer, fuel gauge, gear indicator, tachometer (basic display).
Traction Control:
On-Demand All-Wheel Drive system provides enhanced traction in challenging conditions.
Accessories Support:
Provision for accessory lighting, winches, and other electrical add-ons.
Engine Oil Change:
Typically every 50-100 operating hours or annually (refer to manual for precise intervals and conditions).
Air Filter Service:
Inspect every 25-50 hours, clean/replace as needed, more frequently in dusty conditions.
Spark Plug Replacement:
Inspect annually or every 100 hours, replace as needed.
Transmission Fluid Change:
Typically every 100-200 operating hours or annually, depending on usage.
Engine Oil Type:
SAE 20W-50 API SG or higher (Polaris brand oil recommended, but API specs are key).
Engine Oil Capacity:
Approximately 2.0-2.5 quarts (refer to specific model manual for exact capacity).
Transmission Fluid Type:
Polaris Transmission Fluid (PTF) or equivalent synthetic transmission fluid meeting specified viscosity.
Coolant Type:
Ethylene glycol based antifreeze/coolant, typically 50/50 mix with distilled water.
Belt Wear:
PVT belt wear and failure can occur with aggressive use or improper maintenance. Monitor belt condition and adjust/replace as needed.
Carburetor Tuning:
Carburetors may require periodic adjustment or cleaning for optimal performance, especially at different altitudes.
Suspension Bushings:
Wear on suspension bushings and ball joints is common with heavy use and can lead to play and noise.
Electrical Connections:
Corrosion or loose connections in electrical components can cause intermittent issues.
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer known for snowmobiles, ATVs, and off-road vehicles.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, known for its comfort, AWD, and work/recreation versatility.
Xplorer Worker Role:
The 'Xplorer' and 'Worker' designations often implied enhanced off-road capability, durability, and features geared towards more demanding work applications, though models were often shared across series with minor variations.
Manufacturing Location:
Primarily manufactured in the United States (e.g., Roseau, Minnesota).
