Basic Information Identification Make: Polaris Model Family: Sportsman, Xplorer, Worker Covered Models: Sportsman 400, Sportsman 500, Xplorer 500, Worker 400, Worker 500 Covered Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Vehicle Type: All-Terrain Vehicle (ATV) Codes Manual Product Name: 1996-2003 POLARIS SPORTSMAN / XPLORER / WORKER 400 & 500 ATV Service Repair Manual PDF Download Introduction Market Position Target Audience: Polaris ATV owners, DIY mechanics, service technicians, restoration enthusiasts Competitive Analysis Comparison To Dealer Manuals: Identical to manuals used by local dealers, providing professional-grade information Key Features Value Proposition: Inexpensive way to keep ATVs working properly, saves money on repairs, enhances owner knowledge Unique Selling Points: Comprehensive coverage for a wide range of years and specific models, including special editions; printable pages for workshop use; full diagnostic and repair procedures. Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Troubleshooting, Rebuilding, Restoration Specific Models Covered: 1996 Sportsman 500, 1997 Sportsman 500, 1997 Xplorer 500, 1998 Sportsman 500, 1998 Worker 500, 1999 Sportsman 500, 1999 Worker 500, 1999 Sportsman 500 RSE, 2000 Sportsman 500, 2000 Worker 500, 2000 Sportsman 500 RSE, 2001 Sportsman 400, 2001 Sportsman 500 DUSE, 2001 Sportsman 500 H.O., 2002 Sportsman 400, 2002 Worker 400 (International), 2002 Sportsman 400 ASEI, 2002 Sportsman 400 DUSE, 2002 Sportsman 500 H.O., 2002 Worker 500 (International), 2002 Sportsman 500 RSEI, 2002 Sportsman 500 DUSE1, 2002 Sportsman 500 H.O. Desert, 2002 Sportsman 500 H.O. Freedom, 2003 Sportsman 400, 2003 Sportsman 500 H.O., 2003 Sportsman Ducks Unlimited Special Edition (DUSE), 2003 Sportsman Remington Special Edition (RSE), 2003 Sportsman 400 Desert Page Count Total Pages: 500+ Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF Download Manual Coverage Systems Covered Engine: Engine overhaul, diagnosis, starting system, charging system, ignition system, electronic throttle control Transmission: Transmission operation, repair, maintenance (specific details on type not provided in this snippet) Electrical System: Wiring diagrams, lighting, ignition, charging system, starter system, electronic components Fuel System: Fuel delivery, carburetor/fuel injection (model dependent), fuel pump, fuel tank Suspension: Front and rear suspension components, shock absorbers, bushings, adjustments Braking System: Brake pad replacement, caliper service, hydraulic system, bleeding procedures Cooling System: Radiator, coolant, fan, water pump, thermostat Drive Train: Drivetrain components, shafts, differentials, AWD system (if applicable) Body And Frame: Body panels, fenders, chassis inspection, seat mounting Controls: Handlebars, throttle control, brake levers, shifter mechanisms Engine Control: Electronic throttle control system diagnosis and repair Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, lubrication, pre-ride checks Troubleshooting: Diagnostic flowcharts for starting difficulties, engine performance issues, electrical problems, charging system faults Repair: Detailed step-by-step repair instructions for all major components and systems Rebuilds: Engine rebuild procedures, transmission overhaul, carburetor/fuel injection system rebuild Diagnostics: System analysis, component testing, fault identification using diagnostic charts and specifications Restoration: Guidance for refurbishing and restoring vintage models Torque Specifications: Detailed torque specifications for all fasteners and critical components Lubrication Guidelines: Specific lubrication points and recommended lubricant types Fastener Information: Details on fasteners, including thread locking compound recommendations Gasket Sealant Use: Information on RTV gasket sealant application Safety Handling: Guidelines for handling gasoline safely and general safety precautions Technical Depth Depth: Comprehensive, from basic maintenance to complete engine rebuilds and advanced diagnostics Documentation Quality: Detailed illustrations, step-by-step instructions, diagnostic procedures, repair specifications Diagnostic Tools Mentioned: Troubleshooting instruments and procedures for engine, starting, and charging systems Illustration Quality: Detailed illustrations supporting step-by-step instructions Manual Specifications File Format Format: PDF Print Quality Printable: Yes, all pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) Searchability Text Search: Likely searchable due to PDF format (depending on OCR quality) Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (specifics vary by model, but likely a Polaris engine) Engine Type Variant 400 Displacement 400: Approximately 375-400cc (typical for this era) Engine Type Variant 500 Displacement 500: Approximately 499-500cc Performance Horsepower Range: Estimated 20-30 HP (varies significantly by specific model year and variant) Torque Range: Estimated 25-35 ft-lbs (varies significantly by specific model year and variant) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni) or early electronic fuel injection (EFI) for H.O. models Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) or similar electronic ignition system Cooling System Cooling Method: Liquid-cooled (most models) Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with high/low range and reverse Features Drive Modes: 2WD/AWD selectable (model dependent) Dimensions Exterior General Configuration: Riding position, handlebars, footwells, cargo racks Weights Dry Weight Range: Approximately 550-650 lbs (1996-2003 models, varies by exact configuration) Safety Features Ratings Safety Standards: Compliance with relevant ATV safety standards for the era Active Features Braking System Type: Hydraulic disc brakes (front and rear) Passive Features Throttle Control: Thumb throttle with safety interlock features Technology Features Infotainment Features: Basic instrumentation: speedometer, odometer, hour meter, warning lights. No advanced infotainment systems typically found in this...