Model:
Sportsman 400, Sportsman 500, Xplorer 500 4x4
Year Range Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Chassis Codes:
Specific chassis codes for each model variant within the year range are detailed within the manual.
Vin Decoder Information:
Likely includes VIN interpretation for model year and configuration verification.
Target Audience:
Owners, independent repair shops, and professional technicians servicing Polaris Sportsman and Xplorer ATVs.
Value Proposition:
Provides essential, accurate, and detailed technical information for maintaining and repairing these versatile off-road vehicles, saving time and money on repairs.
Alternative Resources:
Offers superior detail compared to generic repair guides; factory-level accuracy is paramount for these complex machines.
Ease Of Use:
Digital format allows for quick searches and easy access to specific repair procedures.
Comprehensiveness:
Covers all aspects of vehicle maintenance, diagnosis, and repair, ensuring users have the information needed for any task.
Market Coverage:
North America (USA, Canada) and potentially other regions depending on model availability.
Geographic Coverage:
Primarily North American market specifications, though many procedures are universal.
Estimated Page Count:
Likely exceeds 500 pages, typical for comprehensive factory service manuals covering multiple model years and variations.
Type:
Factory Service Repair Workshop Manual
Purpose:
Diagnosis, repair, maintenance, and overhaul of all major vehicle systems.
Powertrain:
Engine mechanical, lubrication system, cooling system, fuel system (carburetor and EFI depending on model), exhaust system, ignition system, clutch, transmission (PVT - Polaris Variable Transmission), drive shafts, differentials, final drive.
Chassis And Suspension:
Frame, suspension components (front and rear A-arms, shocks, springs), steering system, wheels, tires, braking system (hydraulic, disc brakes front and rear), 4x4 engagement system (on demand 4WD).
Electrical And Electronics:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlights, taillights, brake lights), ignition system (CDI, coils), instrumentation, wiring diagrams for all circuits.
Body And Trim:
Body panels, fenders, racks, seat, handlebars, controls, lighting fixtures.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points, brake fluid flush, coolant checks and replacement, valve adjustments (if applicable).
Diagnostic Procedures:
Troubleshooting guides for common problems, symptom-based diagnostics, electrical system fault finding, engine performance issues, starting and charging system diagnostics.
Repair And Overhaul:
Engine disassembly and reassembly, carburetor rebuilding, EFI system diagnosis and repair, transmission removal and repair, suspension component replacement, brake system overhaul, electrical component replacement, steering system repair.
Special Tool Usage:
Identification and application of specialized tools required for specific repairs.
Depth:
Comprehensive factory-level detail, covering everything from basic adjustments to complete engine and transmission rebuilds.
Diagnostic Complexity:
Advanced diagnostics for electrical, fuel, and mechanical systems, including detailed fault codes and troubleshooting trees.
Torque Specifications:
Precise torque values for all critical fasteners and engine components.
Clearances And Tolerances:
Specific engine component clearances and manufacturing tolerances for proper assembly and operation.
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable PDF for easy navigation and information retrieval.
Resolution:
High-resolution scans ensuring clarity of diagrams, schematics, and text.
Scalability:
Printable at various sizes without loss of detail, suitable for home or professional printing.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Completeness:
Complete factory service manual, no missing sections or abridgments.
Licensing:
No expiry dates, perpetual access.
Engine Type 400:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (likely Polaris engine)
Engine Displacement 400:
Approximately 375cc to 400cc (specific figure depends on exact sub-model)
Engine Type 500:
Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (likely Polaris engine, e.g., the 'Big Boss' engine)
Engine Displacement 500:
Approximately 499cc to 500cc
Bore X Stroke:
Specifics provided in manual for each engine variant.
Horsepower Approx 500:
Typically in the range of 25-30 HP, depending on exact tuning and model year.
Torque Approx 500:
Torque figures will be detailed in the manual for optimal low-end grunt.
Fuel Delivery 400 Early:
Carbureted (e.g., Mikuni BSR series)
Fuel Delivery 400 Late/500:
Fuel Injection (EFI) may be present on later models or specific variants. Manual will specify.
Fuel Type:
Unleaded gasoline, Octane rating specified in manual (typically 87 or higher).
Ignition Type:
CDI (Capacitor Discharge Ignition) or similar electronic ignition.
Spark Plug Type:
Specific spark plug part numbers and gap settings provided in manual.
Type:
Polaris Variable Transmission (PVT) with automatic centrifugal clutch and belt drive.
Gear Selection:
H (High), L (Low), N (Neutral), R (Reverse), P (Park) if applicable.
Optional Transmissions:
No manual transmission options typically available for these models.
Drive System:
Shaft-driven, 4x4 On-Demand system with automatic torque sensing front differential.
Gear Ratio Specifications:
Detailed gear ratios for High, Low, and Reverse gears are included in the manual.
Transmission Fluid Type:
Specific Polaris PVT fluid or equivalent recommended, as detailed in the manual.
Transmission Fluid Capacity:
Capacity for PVT system specified in manual.
Length:
Approx. 81-83 inches (model dependent).
Width:
Approx. 46-48 inches (model dependent).
Height:
Approx. 45-48 inches (model dependent).
Wheelbase:
Approx. 50-52 inches (model dependent).
Ground Clearance:
Typically 10-11 inches.
Dry Weight:
Approx. 550-600 lbs (model dependent).
Curb Weight:
Weights including fluids and battery specified in manual.
Towing Capacity:
Typically rated for a hitch receiver, often around 1200-1500 lbs, consult manual for specifics.
Rack Capacity Front:
Approx. 100 lbs.
Rack Capacity Rear:
Approx. 200 lbs.
Tire Size Front:
Commonly 25x8-12 or 25x10-12.
Tire Size Rear:
Commonly 25x10-12 or 25x12-12.
Tire Pressure:
Specified in manual, typically around 5-7 PSI for off-road use.
Atv Safety Standards:
Adheres to industry safety standards for ATVs of its era. Manual will highlight safety precautions.
Braking System:
Hydraulic disc brakes front and rear, integrated braking lever, and foot-operated rear brake.
4X4 Engagement:
On-demand 4WD system for enhanced traction in off-road conditions.
Lighting:
Dual headlights, taillight, and brake light for visibility.
Rollover Protection:
No specific ROPS structure; operator assumes responsibility for safe operation.
Recommendations:
Manual strongly advises reading the owner's manual and completing ATV safety training.
Infotainment Systems:
These models generally do not feature advanced infotainment systems; focus is on core functionality.
Driver Assistance Features:
Limited to functional systems like 4x4 engagement. No electronic driver aids like ABS or traction control.
Connectivity Features:
No electronic connectivity features.
Gauge Cluster:
Basic analog gauges (speedometer, tachometer if equipped, fuel gauge, temperature gauge) and indicator lights.
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first. Consult manual for precise intervals and conditions.
Air Filter Maintenance:
Recommended inspection every 20-40 hours, cleaning/replacement as needed based on operating conditions.
Spark Plug Replacement:
Recommended replacement every 100-200 hours or annually.
Brake Fluid Flush:
Recommended every 12-24 months.
Coolant Replacement:
Typically every 24 months or as per manual recommendations.
Engine Oil Type:
Polaris PS-4 (or equivalent synthetic 0W-40 or 10W-40, consult manual for exact grade and API rating).
Engine Oil Capacity:
Approximately 2.0-2.5 quarts (1.9-2.4 liters) with filter. Manual specifies exact capacity.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual specifies Polaris brand or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual specifies precise type.
Gearcase Oil Type:
Polaris Gearcase Lubricant or equivalent. Manual specifies viscosity and type.
Common Wear Items:
Drive belts (PVT), suspension bushings, ball joints, tie rod ends, wheel bearings, brake pads/rotors, starter solenoid.
Engine Issues:
Carburetor tuning/cleaning on older models, potential starter motor issues, camshaft wear on high-mileage units.
Drivetrain Issues:
PVT belt slippage or breakage due to age or abuse, potential CV joint boot tears, 4x4 engagement system minor issues.
Belt Inspection:
Regular inspection of the PVT belt for wear, cracks, and proper tension is crucial.
Cooling System Maintenance:
Keeping the radiator clean and ensuring proper coolant flow is vital to prevent overheating, especially during demanding use.
Polaris History:
Polaris Industries has a long history of producing off-road vehicles, including snowmobiles and ATVs, known for innovation and ruggedness.
Sportsman Lineage:
The Sportsman line, introduced in the early 1990s, became a benchmark for utility and comfort in the ATV market. This era saw significant development in suspension and drivetrain technology.
Xplorer Lineage:
The Xplorer series often targeted a more aggressive or specialized off-road performance niche compared to the standard Sportsman.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Production Period:
These models were part of Polaris's robust lineup during a period of significant growth and technological advancement in the ATV industry.
Industry Awards:
While specific awards for these exact years/models might be hard to pinpoint without deep historical archives, Polaris ATVs of this era were consistently recognized for their utility, comfort, and innovation, contributing to their market leadership.
Consumer Ratings:
Owners generally praised the reliability and workhorse capability of these models, making them popular for utility and recreational purposes.
Certifications:
Manufactured to meet applicable industry safety and emissions standards of their production years.
