Model:
Sportsman 400 / 500, Xplorer 500
Model Variants:
Sportsman 400, Sportsman 500, Xplorer 500
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Chassis Codes:
Likely specific to each model variant and year, common chassis types include tube frame construction
Engine Codes:
Varies by year and model variant, typically referring to engine displacement and type (e.g., 'A96AA' for a 1996 400 or 'A99AA' for a 1999 500)
Category:
All-Terrain Vehicle (ATV) / Utility Quad
Target Audience:
Owners, DIY mechanics, and professional technicians performing maintenance and repairs on Polaris Sportsman and Xplorer models
Competitors:
Yamaha Kodiak/Grizzly, Honda Foreman/Rancher, Suzuki King Quad, Kawasaki Prairie/Bayou
Vehicle Type:
4x4 ATVs known for their utility, comfort, and trail-riding capabilities during their production era
Manual Value Proposition:
Provides the essential, factory-authorized technical data required for accurate and efficient servicing, saving time and money on repairs
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Frame, Bodywork, Steering, Maintenance, Troubleshooting, Specifications
Estimated Page Count:
500+ pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital File (likely PDF)
Engine:
Detailed disassembly, assembly, overhaul, and troubleshooting for all engine types used in the covered models (e.g., 375cc, 499cc OHV V-twin)
Transmission Drivetrain:
Covers automatic transmission (PVT - Polaris Variable Transmission), final drive, driveshafts, CV joints, and differential assemblies
Brakes:
Hydraulic disc brake systems, including front and rear caliper overhaul, brake line replacement, master cylinder service, and bleeding procedures
Electrical System:
Wiring diagrams, ignition system (CDI, coils, spark plugs), starting system (starter motor, solenoid), lighting, battery maintenance, and electrical component testing
Fuel System:
Carburetor (e.g., Mikuni, Keihin) overhaul, jetting, fuel pump, fuel lines, and fuel tank service
Suspension Steering:
Front and rear independent suspension (e.g., MacPherson strut, trailing arm), shock absorber service, ball joint replacement, steering column and tie rod end service
Frame Bodywork:
Frame inspection and repair, body panel removal and installation, seat service, and accessory mounting
Maintenance:
Regular service intervals, oil changes, filter replacements, spark plug service, chain/belt adjustment, lubrication points, and battery care
Troubleshooting:
Diagnostic charts and procedures for common problems such as starting issues, poor running, electrical faults, and drivetrain malfunctions
Repair Rebuild:
Step-by-step instructions for component disassembly, inspection, repair, reassembly, and adjustment for all major systems
Torque Specifications:
Detailed torque values for all critical fasteners throughout the vehicle
Depth:
Comprehensive, covering everything from basic maintenance and fluid checks to complete engine and transmission overhauls, electrical diagnostics, and suspension rebuilds
Digital Format:
PDF (Portable Document Format) - enables easy searching, printing, and viewing on various devices
Scan Resolution:
High-resolution scans ensuring clarity of diagrams, illustrations, and text
Binding:
Not applicable (digital download)
Paper Quality:
Not applicable (digital download)
Text Search:
Likely text-searchable PDF, allowing users to quickly find specific information
Bookmark Structure:
Professionally formatted PDFs often include bookmarks for easy navigation between sections
Engine Type:
4-stroke, OHV (Overhead Valve), V-twin cylinder
Displacement 400:
Approximately 375cc (specific variations may exist)
Displacement 500:
Approximately 499cc (specific variations may exist)
Horsepower Range:
Estimated 25-35 HP depending on specific model and year
Torque Characteristics:
Designed for low-end torque for pulling and climbing
Carburetor Type:
Mikuni or Keihin, single carburetor (e.g., VM34/1 on some 500 models, BD/BS series on others)
Fuel Type:
Unleaded Gasoline (Octane rating typically 87 minimum)
Cooling Method:
Liquid-cooled
Oil Type Specification:
SAE 20W-50 API SG or higher (confirm with specific manual/owner's manual for exact spec)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic, Polaris Variable Transmission (PVT) with Hi/Lo range and Reverse
Gear Selection:
Forward (High/Low), Neutral, Reverse
Drive System:
Shaft drive, 4WD with Active Descent Control (ADC) on some models
Transmission Fluid Type:
Polaris Angle Drive Fluid (PS-4) for front and rear differentials, PVT fluid spec varies (check manual, sometimes SAE 10W-40 or specific PVT fluids)
Safety Standards:
Designed to meet ANSI standards for ATVs (where applicable at the time of manufacture)
Braking System:
Hydraulic disc brakes front and rear
Throttle Limiter:
Some models may feature adjustable throttle limiters for beginner riders
Lighting:
Headlights, taillight/brake light
Rollover Protection:
Handlebar design and frame structure provide some protection, though not equivalent to enclosed cabins
Audio System:
Typically no integrated infotainment system on these models; audio is incidental to engine and operational sounds.
Active Descent Control:
Available on some 4x4 models to assist with downhill braking
Usb Ports:
Not standard equipment on these models
Dashboard Gauges:
Speedometer, odometer, fuel gauge, neutral/reverse indicator lights, oil pressure warning light, engine temperature warning light
Oil Change Interval:
Every 100 hours or 6 months (whichever comes first) for engine oil and filter
Air Filter Cleaning:
Inspect and clean every 25 hours, replace as needed
Spark Plug Service:
Inspect every 50 hours, replace as needed. Recommended gap: 0.028-0.031 inches (check manual for exact plug and gap)
Brake Fluid Flush:
Recommended every 1-2 years
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (check dipstick and manual for exact fill)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Differential Fluid Type:
Polaris Premium Gearcase Lubricant or SAE 80W-90 API GL-5 (check manual)
Common Wear Items:
PVT belt wear, voltage regulator failures, brake pad wear, steering component wear (tie rods, ball joints)
Carburetor Cleaning:
Periodic cleaning and adjustment may be required due to fuel quality or usage
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles
Sportsman Lineage:
The Sportsman line, introduced in the early 1990s, became a benchmark for comfort, handling, and utility in the ATV market. The 400 and 500 models represent key iterations in its development.
Xplorer Lineage:
The Xplorer was positioned as a more rugged, utility-focused ATV, often sharing powertrains and chassis components with the Sportsman line but emphasizing work capabilities.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries
Industry Acclaim:
Polaris Sportsman models of this era were generally well-regarded for their comfort, ride quality, and utility, contributing to Polaris's strong market share in the ATV segment.
Consumer Reviews:
Owners often praised the powerful engines (especially the 500), comfortable suspension, and reliable 4WD systems, though some noted occasional electrical gremlins or starter issues
