POLARIS SPORTSMAN 400 500 XPLORER 500 ATV Service Repair Manual

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 / Xplorer 500 Product Type: Service Repair Manual Format: PDF Download Codes Common Model Codes: A03CH50AA (Sportsman 400), A03CH50AB (Sportsman 400), A04CH50AA (Sportsman 400), A05CH50AA (Sportsman 400), A06CH50AA (Sportsman 400), A03CH50BB (Sportsman 400), A03CH50CB (Sportsman 400), A04CH50BB (Sportsman 400), A05CH50BB (Sportsman 400), A06CH50BB (Sportsman 400), A03CB50AA (Sportsman 500), A04CB50AA (Sportsman 500), A05CB50AA (Sportsman 500), A06CB50AA (Sportsman 500), A07CB50AA (Sportsman 500), A08CB50AA (Sportsman 500), A09CB50AA (Sportsman 500), A10CB50AA (Sportsman 500), A11CB50AA (Sportsman 500), A12CB50AA (Sportsman 500), A03CH50FB (Sportsman 500), A04CH50FB (Sportsman 500), A05CH50FB (Sportsman 500), A06CH50FB (Sportsman 500), A07CH50FB (Sportsman 500), A08CH50FB (Sportsman 500), A09CH50FB (Sportsman 500), A10CH50FB (Sportsman 500), A11CH50FB (Sportsman 500), A12CH50FB (Sportsman 500), A03CB50FB (Sportsman 500), A04CB50FB (Sportsman 500), A05CB50FB (Sportsman 500), A06CB50FB (Sportsman 500), A07CB50FB (Sportsman 500), A08CB50FB (Sportsman 500), A09CB50FB (Sportsman 500), A10CB50FB (Sportsman 500), A11CB50FB (Sportsman 500), A12CB50FB (Sportsman 500), A03CH50FC (Sportsman 500), A04CH50FC (Sportsman 500), A05CH50FC (Sportsman 500), A06CH50FC (Sportsman 500), A07CH50FC (Sportsman 500), A08CH50FC (Sportsman 500), A09CH50FC (Sportsman 500), A10CH50FC (Sportsman 500), A11CH50FC (Sportsman 500), A12CH50FC (Sportsman 500), A03CB50FC (Sportsman 500), A04CB50FC (Sportsman 500), A05CB50FC (Sportsman 500), A06CB50FC (Sportsman 500), A07CB50FC (Sportsman 500), A08CB50FC (Sportsman 500), A09CB50FC (Sportsman 500), A10CB50FC (Sportsman 500), A11CB50FC (Sportsman 500), A12CB50FC (Sportsman 500), A02CH50AA (Xplorer 500), A02CH50AB (Xplorer 500), A02CH50AC (Xplorer 500), A02CH50AD (Xplorer 500), A02CH50AE (Xplorer 500), A02CH50AF (Xplorer 500), A02CH50AG (Xplorer 500), A02CH50AH (Xplorer 500), A03CH50FB (Xplorer 500), A04CH50FB (Xplorer 500), A05CH50FB (Xplorer 500), A06CH50FB (Xplorer 500), A07CH50FB (Xplorer 500), A08CH50FB (Xplorer 500), A09CH50FB (Xplorer 500), A10CH50FB (Xplorer 500), A11CH50FB (Xplorer 500), A12CH50FB (Xplorer 500) 👋 Introduction Market Position Segment: Utility/Recreational All-Terrain Vehicle (ATV) Target User: Off-road enthusiasts, farmers, hunters, recreational riders requiring robust and reliable utility vehicles. Competitive Analysis Competitors: Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Suzuki KingQuad, Kawasaki Brute Force/Prairie. Key Features Features: Long-travel suspension, powerful 4-stroke engines, selectable 2WD/4WD, cargo racks, robust chassis, comfort and utility focus. Manual Purpose Purpose: To provide comprehensive guidance for maintenance, repair, and restoration of Polaris Sportsman 400, 500, and Xplorer 500 ATVs. 📋 Manual Details Coverage Areas Applicable Years: 2002-2012 (Specific model years may vary by sub-model and region; extensive coverage across this range is typical for such manuals) Page Count Estimated Pages: Hundreds (as stated, typically 400-700+ pages for comprehensive service manuals covering multiple variants) Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, rebuild procedures, piston, rings, cylinder, crankshaft, connecting rods, camshaft, valves, timing, lubrication system, cooling system. Fuel System: Fuel pump, carburetor (or EFI components), fuel filter, fuel lines, fuel tank, fuel system diagnostics. Ignition System: Ignition coils, spark plugs, CDI unit, timing, troubleshooting. Drivetrain Transmission: Automatic transmission (PVT - Polaris Variable Transmission) removal, disassembly, assembly, inspection, belt replacement, clutch system (primary and secondary), final drive, differential. Suspension Steering: Front and rear suspension (A-arms, shocks, springs), steering system (handlebar, steering shaft, tie rods, knuckles), wheel bearings, alignment. Braking System: Hydraulic brake system, brake calipers, brake pads, brake lines, master cylinder, brake fluid, parking brake, bleeding procedures. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, fuses, relays, ignition switch, control modules. Bodywork Frame: Frame inspection and repair, body panels, fenders, racks, seat, plastics, decals, lighting fixtures. Cooling System: Radiator, fan, coolant, hoses, thermostat, water pump, flush and fill procedures. Procedures Included Maintenance Schedules: Regularly scheduled maintenance intervals (e.g., oil changes, filter replacements, lubrication points, valve adjustments, belt checks). Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts, error codes. Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Wiring Diagrams: Comprehensive electrical schematics for all circuits, component identification, connector pinouts. Torque Specifications: Precise torque values for all fasteners and critical components. Special Tools: Identification and usage instructions for specialized tools required for certain procedures. Specifications Data: All essential technical data, measurements, tolerances, and specifications for all vehicle systems. Technical Depth Depth: Comprehensive (covers basic maintenance through complete engine and transmission rebuilds, electrical diagnostics, and frame repair) 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable (typically, depending on PDF creation) Print Quality Quality: High-resolution images and diagrams, printable pages Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC, 2-Valve (Typical for these models, variations exist) Displacement 400: Approx. 375cc - 400cc (Exact displacement varies by specific model year and sub-model) Displacement 500: Approx. 499cc - 500cc (Exact displacement varies by specific model year and sub-model) Performance Horsepower Range: Typically in the 25-35 HP range, depending on engine size and tuning. Torque Range: Engine torque is optimized for low-end pulling power and trail riding. Fuel System Carburetor Type: Mikuni BSR series (common) or Keihin, specific size varies by model and year. Fuel...

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Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 / 500 / Xplorer 500

Product Type:

Service Repair Manual

Format:

PDF Download

Codes

Common Model Codes:

A03CH50AA (Sportsman 400), A03CH50AB (Sportsman 400), A04CH50AA (Sportsman 400), A05CH50AA (Sportsman 400), A06CH50AA (Sportsman 400), A03CH50BB (Sportsman 400), A03CH50CB (Sportsman 400), A04CH50BB (Sportsman 400), A05CH50BB (Sportsman 400), A06CH50BB (Sportsman 400), A03CB50AA (Sportsman 500), A04CB50AA (Sportsman 500), A05CB50AA (Sportsman 500), A06CB50AA (Sportsman 500), A07CB50AA (Sportsman 500), A08CB50AA (Sportsman 500), A09CB50AA (Sportsman 500), A10CB50AA (Sportsman 500), A11CB50AA (Sportsman 500), A12CB50AA (Sportsman 500), A03CH50FB (Sportsman 500), A04CH50FB (Sportsman 500), A05CH50FB (Sportsman 500), A06CH50FB (Sportsman 500), A07CH50FB (Sportsman 500), A08CH50FB (Sportsman 500), A09CH50FB (Sportsman 500), A10CH50FB (Sportsman 500), A11CH50FB (Sportsman 500), A12CH50FB (Sportsman 500), A03CB50FB (Sportsman 500), A04CB50FB (Sportsman 500), A05CB50FB (Sportsman 500), A06CB50FB (Sportsman 500), A07CB50FB (Sportsman 500), A08CB50FB (Sportsman 500), A09CB50FB (Sportsman 500), A10CB50FB (Sportsman 500), A11CB50FB (Sportsman 500), A12CB50FB (Sportsman 500), A03CH50FC (Sportsman 500), A04CH50FC (Sportsman 500), A05CH50FC (Sportsman 500), A06CH50FC (Sportsman 500), A07CH50FC (Sportsman 500), A08CH50FC (Sportsman 500), A09CH50FC (Sportsman 500), A10CH50FC (Sportsman 500), A11CH50FC (Sportsman 500), A12CH50FC (Sportsman 500), A03CB50FC (Sportsman 500), A04CB50FC (Sportsman 500), A05CB50FC (Sportsman 500), A06CB50FC (Sportsman 500), A07CB50FC (Sportsman 500), A08CB50FC (Sportsman 500), A09CB50FC (Sportsman 500), A10CB50FC (Sportsman 500), A11CB50FC (Sportsman 500), A12CB50FC (Sportsman 500), A02CH50AA (Xplorer 500), A02CH50AB (Xplorer 500), A02CH50AC (Xplorer 500), A02CH50AD (Xplorer 500), A02CH50AE (Xplorer 500), A02CH50AF (Xplorer 500), A02CH50AG (Xplorer 500), A02CH50AH (Xplorer 500), A03CH50FB (Xplorer 500), A04CH50FB (Xplorer 500), A05CH50FB (Xplorer 500), A06CH50FB (Xplorer 500), A07CH50FB (Xplorer 500), A08CH50FB (Xplorer 500), A09CH50FB (Xplorer 500), A10CH50FB (Xplorer 500), A11CH50FB (Xplorer 500), A12CH50FB (Xplorer 500)

👋 Introduction

Market Position

Segment:

Utility/Recreational All-Terrain Vehicle (ATV)

Target User:

Off-road enthusiasts, farmers, hunters, recreational riders requiring robust and reliable utility vehicles.

Competitive Analysis

Competitors:

Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Suzuki KingQuad, Kawasaki Brute Force/Prairie.

Key Features

Features:

Long-travel suspension, powerful 4-stroke engines, selectable 2WD/4WD, cargo racks, robust chassis, comfort and utility focus.

Manual Purpose

Purpose:

To provide comprehensive guidance for maintenance, repair, and restoration of Polaris Sportsman 400, 500, and Xplorer 500 ATVs.

📋 Manual Details

Coverage Areas

Applicable Years:

2002-2012 (Specific model years may vary by sub-model and region; extensive coverage across this range is typical for such manuals)

Page Count

Estimated Pages:

Hundreds (as stated, typically 400-700+ pages for comprehensive service manuals covering multiple variants)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, rebuild procedures, piston, rings, cylinder, crankshaft, connecting rods, camshaft, valves, timing, lubrication system, cooling system.

Fuel System:

Fuel pump, carburetor (or EFI components), fuel filter, fuel lines, fuel tank, fuel system diagnostics.

Ignition System:

Ignition coils, spark plugs, CDI unit, timing, troubleshooting.

Drivetrain Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) removal, disassembly, assembly, inspection, belt replacement, clutch system (primary and secondary), final drive, differential.

Suspension Steering:

Front and rear suspension (A-arms, shocks, springs), steering system (handlebar, steering shaft, tie rods, knuckles), wheel bearings, alignment.

Braking System:

Hydraulic brake system, brake calipers, brake pads, brake lines, master cylinder, brake fluid, parking brake, bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, fuses, relays, ignition switch, control modules.

Bodywork Frame:

Frame inspection and repair, body panels, fenders, racks, seat, plastics, decals, lighting fixtures.

Cooling System:

Radiator, fan, coolant, hoses, thermostat, water pump, flush and fill procedures.

Procedures Included

Maintenance Schedules:

Regularly scheduled maintenance intervals (e.g., oil changes, filter replacements, lubrication points, valve adjustments, belt checks).

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, fault finding charts, error codes.

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits, component identification, connector pinouts.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Special Tools:

Identification and usage instructions for specialized tools required for certain procedures.

Specifications Data:

All essential technical data, measurements, tolerances, and specifications for all vehicle systems.

Technical Depth

Depth:

Comprehensive (covers basic maintenance through complete engine and transmission rebuilds, electrical diagnostics, and frame repair)

📊 Manual Specifications

File Format

Format:

Searchability:

Text-searchable (typically, depending on PDF creation)

Print Quality

Quality:

High-resolution images and diagrams, printable pages

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Liquid-Cooled, SOHC, 2-Valve (Typical for these models, variations exist)

Displacement 400:

Approx. 375cc - 400cc (Exact displacement varies by specific model year and sub-model)

Displacement 500:

Approx. 499cc - 500cc (Exact displacement varies by specific model year and sub-model)

Performance

Horsepower Range:

Typically in the 25-35 HP range, depending on engine size and tuning.

Torque Range:

Engine torque is optimized for low-end pulling power and trail riding.

Fuel System

Carburetor Type:

Mikuni BSR series (common) or Keihin, specific size varies by model and year.

Fuel Injection:

Some later models may feature Electronic Fuel Injection (EFI).

Lubrication System

Oil Type Recommendation:

SAE 10W-40 or SAE 5W-50 Synthetic ATV Oil (Always refer to manual for specific API rating/classification)

Oil Capacity:

Approximately 2.0 - 2.5 quarts (1.9 - 2.4 liters) with filter change (Refer to manual for exact capacity)

Ignition System

Spark Plug Type:

NGK CR7E or similar (Specific type and gap are critical and detailed in the manual)

🔧 Transmission

Standard

Transmission Type:

Polaris Variable Transmission (PVT) Automatic with Engine Braking

Drive Modes:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive (2WD/AWD On-Demand)

Features

Clutch System:

Heavy-duty CVT system with primary (drive) and secondary (driven) clutches, belt-driven.

Belt Maintenance:

Critical inspection for wear, cracks, and proper tension; replacement intervals are key.

📐 Dimensions

Exterior

Length:

Approx. 81-83 inches (205-211 cm)

Width:

Approx. 46-48 inches (117-122 cm)

Height:

Approx. 48-50 inches (122-127 cm)

Weights

Dry Weight:

Approx. 550-650 lbs (250-295 kg)

Ground Clearance:

Approx. 10-12 inches (25-30 cm)

Cargo

Front Rack Capacity:

Approx. 100 lbs (45 kg)

Rear Rack Capacity:

Approx. 200 lbs (90 kg)

Towing

Towing Capacity:

Typically 1,200 - 1,500 lbs (544 - 680 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI and SFIA standards for ATVs.

Active Features

Engine Braking:

PVT system provides effective engine braking on descents.

On Demand AWD:

Electronic control for switching between 2WD and 4WD for optimal traction.

Passive Features

Ergonomics:

Handlebar design, seating position, and controls are engineered for rider comfort and control.

Lighting:

Dual headlights, tail light/brake light for visibility.

Braking:

Hydraulic disc brakes on all wheels for reliable stopping power.

💡 Technology Features

Infotainment

Display Features:

Digital instrumentation cluster with speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights (varies by trim).

Driver Assistance

Active Descent Control (ADC) available on some models for controlled downhill braking.

Electronic Power Steering (EPS) available on higher-trim models for reduced steering effort.

Connectivity

Usb Charging:

Some models may feature a 12V accessory outlet or USB charging port.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months (whichever comes first)

Air Filter Cleaning Inspection:

Every 25 hours or monthly; replace as needed.

Spark Plug Check:

Every 100 hours or annually.

Transmission Belt Inspection:

Every 50 hours or annually; check for wear and damage.

Brake Fluid Flush:

Every 2 years or as recommended.

Fluid Specifications

Engine Oil Specification:

Polaris branded 5W-50 Synthetic or equivalent API SG, JASO MA approved oil.

Coolant Type:

Ethylene glycol based antifreeze, 50/50 mix with distilled water. Polaris recommends their specific coolant.

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Cvt Belt Wear:

Premature belt wear can occur with aggressive riding, improper belt tension, or misalignment. Manual details inspection and replacement.

Carburetor Issues:

Clogging or tuning issues, especially if fuel is left in the carb for extended periods. Fuel stabilizer is recommended.

Suspension Bushings:

Wear on A-arm bushings can lead to play and steering looseness. Regular inspection and replacement are advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, Inc. - a long-standing leader in the powersports industry, known for innovation in ATVs and snowmobiles.

Model Evolution

Lineage:

The Sportsman line is Polaris's flagship utility ATV series, evolving significantly over the years to incorporate advancements in engine technology, suspension, and ergonomics. The 400, 500, and Xplorer 500 models represent key iterations within this popular family.

Production

Production Period:

These models were in production through various iterations from the early 2000s through to the early 2010s.

Manufacturing Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Atv Of The Year:

While specific awards vary by year, the Polaris Sportsman line has consistently been recognized for its utility, performance, and rider comfort, often ranking highly in industry reviews and buyer satisfaction surveys.