Model:
Sportsman 400, Sportsman 500, Xplorer 500 4x4
Product Type:
Workshop Service Repair Manual
Vehicle Type:
All-Terrain Vehicle (ATV)
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Platform Code:
Not specified in provided information (typical for ATVs)
Target Audience:
DIY enthusiasts and experienced mechanics working on Polaris Sportsman and Xplorer ATVs.
Value Proposition:
Provides dealer-level repair information at a fraction of the cost, empowering owners for self-maintenance and repair.
Feature 1:
Searchable PDF for quick information retrieval.
Feature 2:
Printable pages for convenient use in the garage or workshop.
Feature 3:
iPad-ready format, enhancing portability and accessibility.
Completeness Guarantee:
100% complete and intact, no missing or corrupt pages.
Engine Mechanical:
Complete engine disassembly, assembly, troubleshooting, and repair procedures for all applicable engines.
Cooling System:
Radiator, hoses, coolant, thermostat, fan system maintenance and repair.
Fuel System:
Carburetor, fuel pump, fuel lines, fuel tank maintenance and repair.
Drive Shaft:
Driveshaft inspection, U-joints, and related component service.
Drive Belt:
Drive belt inspection, tensioning, and replacement procedures.
Differential Case Assembly:
Front and rear differential inspection, fluid changes, and repair.
Brake System:
Hydraulic system, brake calipers, master cylinder, brake lines, brake pads, and rotors service.
Suspension System:
Front and rear suspension components, shocks, A-arms, bushings, and wheel bearings.
Steering System:
Steering column, tie rods, ball joints, and steering linkage maintenance and repair.
Electrical System:
Complete electrical troubleshooting, wiring diagrams, battery, charging system (stator, regulator), ignition system, lighting, and accessories.
Control System Mechanical:
Throttle controls, brake levers, shifter mechanisms inspection and adjustment.
Emission Control Systems:
Components like charcoal canisters (if applicable to specific models/years).
Transmission And Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission) service, belt inspection/replacement, drive clutch, driven clutch, and final drive maintenance.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tire pressure checks, spark plug service, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common issues, including engine performance problems, electrical faults, and drivetrain issues.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment for all covered systems.
Rebuilds:
Complete disassembly and reassembly of major components like engine, transmission, and differentials.
Wiring Diagrams:
Detailed wiring diagrams for all electrical systems, aiding in diagnosis and repair.
Special Tools:
Identification of necessary special tools for specific repair procedures.
Depth:
Comprehensive, covering basic maintenance to full overhaul and advanced electrical diagnostics.
Illustrations:
Hundreds of detailed illustrations, drawings, and photos to guide procedures.
Detail Level:
Detailed sub-steps, notes, cautions, and warnings for critical information.
Engine Type Details:
Details for both the Sportsman 400 and Sportsman/Xplorer 500 models, likely single-cylinder, 4-stroke internal combustion engines.
Displacement 500Cc Variant:
Approximately 499cc for the 500 models.
Displacement 400Cc Variant:
Approximately 375cc-400cc for the 400 models.
Horsepower Range:
Typically in the range of 25-35 HP depending on the specific model and year (exact figures require specific model lookup).
Fuel Delivery:
Carbureted (specific carburetor model will be detailed in the manual).
Cooling Method:
Liquid-cooled (typical for these models).
Ignition System:
CDI (Capacitor Discharge Ignition) or similar electronic ignition system.
Length:
Varies by specific model, but typically around 80-85 inches (exact dimensions detailed in manual).
Width:
Varies by specific model, but typically around 45-48 inches (exact dimensions detailed in manual).
Height:
Varies by specific model, but typically around 46-49 inches (exact dimensions detailed in manual).
Dry Weight:
Approximately 550-650 lbs depending on model (exact figures detailed in manual).
Towing Capacity:
Typically around 1500 lbs for 500 models (exact figures detailed in manual).
Ground Clearance:
Around 10-11 inches (exact figures detailed in manual).
Engine Oil Change:
Typically every 50-100 operating hours or annually (specific interval detailed in manual).
Gearcase Oil Change:
Recommended at specified intervals, often annually or every 100-200 hours.
Drive Belt Inspection:
Regular inspection recommended, replacement based on wear and performance.
Engine Oil Type:
Refer to manual for specific oil viscosity and API rating (e.g., SAE 10W-40, API SG or higher).
Engine Oil Capacity:
Refer to manual for specific capacity (typically around 2-3 quarts).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for precise specification).
Common Wear Items:
Drive belts, tie rod ends, ball joints, suspension bushings, wheel bearings, and brake pads are common wear items on ATVs of this age.
Electrical Connections:
Corrosion in electrical connectors can be an issue over time, requiring cleaning and dielectric grease.
Carburetor Maintenance:
Carburetors may require periodic cleaning and adjustment due to fuel quality or age.
