Model:
Sportsman, Xplorer, Worker
Applicable Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Primary Model Codes:
Sportsman 500, Xplorer 500, Worker 500, Sportsman 400
Special Editions Covered:
RSE (Remington Special Edition), DUSE (Ducks Unlimited Special Edition), ASEI, Desert, Freedom
Target Audience:
Polaris ATV owners seeking to perform maintenance, diagnostics, and repairs themselves, as well as independent repair shops.
Advantage:
Provides factory-level information, comparable to what dealers and professional mechanics use, for a wide range of popular ATV models and years.
Key Features:
Instant download, comprehensive coverage, detailed illustrations, diagnostic procedures, troubleshooting guides.
Primary Coverage:
1996-2003 Polaris ATV Sportsman Xplorer 500
Additional Models Covered:
Sportsman 400, Worker 400, Worker 500 (International variants)
Estimated Page Count:
Extensive (Specific number not provided, but described as comprehensive with detailed diagrams)
Manual Type:
Factory Service / Repair / Workshop Manual
Format:
PDF (Instant Download)
Engine Systems:
Top End, Lower End, Fuel System, Cooling Systems, Carburetion
Drivetrain Systems:
Clutch/Drive Belt System, Transmission, Final Drive, Front Drive System
Chassis Systems:
Front Suspension, Steering, Rear Suspension, Brakes, Body
Electrical Systems:
Electrical System, Wiring Diagrams
Maintenance:
Lubrication, Maintenance, Tune-Up, Scheduled Maintenance
Repair:
Engine Overhaul, Transmission Repair, Suspension Overhaul, Brake Service, Electrical Component Replacement
Diagnostics:
Troubleshooting Guides, Diagnostic Procedures for All Systems
Technical Instructions:
Step-by-step instructions, exploded views, detailed diagrams
Depth Of Coverage:
Comprehensive: Covers routine maintenance to full engine and component rebuilds, suitable for DIY and professional use.
Key Manual Sections:
General Information, Troubleshooting, Lubrication Maintenance and Tune-Up, Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, Body, 2001-2003 Service Information, Index, Wiring Diagrams.
Print Quality:
High-resolution, printable pages
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Software Requirements:
Adobe PDF Reader, WinZip
Operating System Compatibility:
All Versions of Windows & Mac
Delivery Method:
Instant Download after payment.
Engine Type:
4-stroke, Single-cylinder (details vary by specific model/year, but predominantly 499cc for 500cc models, and likely similar architecture for 400cc models)
Horsepower Range Estimated:
Typically in the range of 25-35 HP for 500cc models, with HO (High Output) versions offering slightly more.
Torque Range Estimated:
Varies by specific engine tuning and displacement, but designed for low-end torque for off-road applications.
Fuel Delivery:
Carbureted (likely Mikuni VM series or similar, specific model depends on year and variant).
Cooling Method:
Liquid-cooled (typical for these models)
Bore Stroke Typical:
For 500cc models, often around 90mm bore x 78mm stroke, specific figures detailed in manual.
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft drive, with selectable 2WD/4WD and often a locking front differential on certain models.
Wheelbase Typical:
Approximately 50-52 inches, varies slightly by model year.
Dry Weight Typical:
Around 600-700 lbs, varies by model and configuration.
Towing Capacity Typical:
Often rated around 1,500 lbs, but specific limits must be confirmed in the manual.
Braking System:
Hydraulic disc brakes (front and rear), single lever operation common.
Lighting:
Headlights, taillight, often integrated into bodywork.
Operator Safety:
Manual emphasizes proper riding techniques, protective gear, and safe operation.
Infotainment System:
Not applicable for this era of ATVs. Focus is on utility and performance.
Driver Assistance Features:
Limited to standard controls. Some models may have electronic fuel injection (EFI) on later HO variants, but carburetion is common.
Connectivity Features:
Not applicable. Focus on mechanical and electrical systems.
Oil Change Interval:
Typically every 50-100 operating hours or annually, specific oil type and capacity detailed in manual.
Spark Plug Replacement:
Recommended at regular intervals, or when inspection indicates wear, specific gap and type in manual.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions.
Engine Oil Type Typical:
SAE 10W-40 or 20W-50, API SG or higher, specific viscosity depends on operating temperature.
Coolant Type:
Ethylene glycol based antifreeze/coolant, specific mix ratio and type detailed in manual.
Gear Oil Type:
Refer to manual for specific front and rear differential/gearcase lubricant requirements.
Common Wear Items:
Drive belts, brake pads, suspension bushings, wheel bearings, and fuel system components are common wear items.
Potential Electrical Issues:
Corrosion in connectors, battery maintenance, and rectifier/stator function can be areas for attention.
Tune Up Items:
Spark plug, air filter, fuel filter, valve lash adjustment (if applicable), carburetor cleaning/adjustment.
Polarishistoy:
Polaris Industries is a long-standing American manufacturer known for powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Sportsman Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving significantly in technology, power, and features throughout the late 90s and early 2000s.
Production Era:
Mid-to-late 1990s and early 2000s, a period of significant growth and innovation for the ATV market.
