This comprehensive service and repair manual provides detailed instructions and specifications for maintaining and repairing your 1996-2003 Polaris Sportsman 400, 500, and Xplorer 500 4x4 series ATV. It covers a wide range of topics, from routine maintenance procedures to complex engine overhauls. Each section of the manual offers in-depth information on the operation of major systems, including diagnostics, troubleshooting, and step-by-step repair procedures. You'll find detailed instructions for removing and installing major components, ensuring you can confidently tackle any repair. The manual is generously illustrated with photographs, diagrams, and illustrations to help you identify parts and understand the correct assembly procedures. Whether you're a seasoned mechanic or a DIY enthusiast, this service manual arms you with the knowledge to handle most repair and maintenance tasks on your Polaris ATV. Save money by performing your own repairs and gain a deeper understanding of your vehicle's inner workings. Gain valuable insights into the intricate details of your ATV, empowering you to confidently diagnose and resolve any issues that may arise. **Covered Models:** * 1996 Polaris Sportsman 500 * 1997 Polaris Sportsman 500 * 1997 Polaris Xplorer 500 * 1998 Polaris Sportsman 500 * 1998 Polaris Worker 500 * 1999 Polaris Sportsman 500 * 1999 Polaris Worker 500 * 1999 Polaris Sportsman 500 RSE * 2000 Polaris Sportsman 500 * 2000 Polaris Worker 500 * 2000 Polaris Sportsman 500 RSE - Remington Special Edition * 2001 Polaris Sportsman 400 * 2001 Polaris Sportsman 500 DUSE * 2001 Polaris Sportsman 500 H.O. * 2001 Polaris Sportsman 500 HO * 2002 Polaris Sportsman 400 * 2002 Polaris Worker 400 (International) * 2002 Polaris Sportsman 400 ASEI * 2002 Polaris Sportsman 400 DUSE * 2002 Polaris Sportsman 500 H.O . * 2002 Polaris Worker 500 (International) * 2002 Polaris Sportsman 500 RSEl * 2002 Polaris Sportsman 500 DUSE1 * 2002 Polaris Sportsman 500 H.O. Desert * 2002 Polaris Sportsman 500 H.O.Freedom * 2003 Polaris Sportsman 400 * 2003 Polaris Sportsman 400 Desert * 2003 Polaris Sportsman 500 H.O. * 2003 Polaris Sportsman Ducks Unlimited Special Edition (DUSE) * 2003 Polaris Sportsman Remington Special Edition (RSE ) **Manual Contents:** * 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 * Supplement 2001-2003 Service Information * Index * Wiring Diagrams

The Polaris Sportsman Xplorer 400 and 500 models, spanning the years 1996 to 2003, represent a popular line of all-terrain vehicles (ATVs) known for their versatility and reliability. These machines are not just for recreational riding but also cater to utility applications, making them suitable for various tasks around the farm, ranch, or even in demanding work environments. The Sportsman 400, powered by a 397cc air-cooled single-cylinder engine, provides a balance of power and fuel efficiency. Meanwhile, the Sportsman 500 boasts a larger 499cc engine, delivering greater torque and pulling power for heavier loads. Both models feature 4x4 capabilities, allowing them to tackle challenging terrain with ease. The Xplorer 500, a distinct version within this range, was introduced in 2000 as a sportier option. It shares the 499cc engine but incorporates a more aggressive design with a lowered suspension and more aggressive tires. This setup prioritizes handling and maneuverability, making it a suitable choice for enthusiasts who enjoy tackling trails and challenging off-road conditions. The Sportsman 400, 500, and Xplorer 500 all feature a durable steel frame, independent front and rear suspension, and reliable disc brakes. They are known for their comfortable riding experience, with ample ground clearance and spacious seating. Whether it's for recreational riding, work duties, or exploring the great outdoors, these Polaris ATVs offer a dependable and capable platform for a wide range of adventures.