This manual covers the Polaris Sportsman 500 and Xplorer 500 models, along with various other specific variants, produced between 1996 and 2003. These versatile All-Wheel Drive (AWD) all-terrain vehicles are powered by a 499cc, four-stroke, SOHC, liquid-cooled, single-cylinder engine and utilize a Variable Transmission (PVT) with engine braking. Known for their robust engineering and capability in demanding off-road conditions, these ATVs have established a strong reputation for reliability and performance, making them a cornerstone of off-road offerings. This comprehensive workshop service repair manual, written in English, provides in-depth technical information for owners and technicians. It details maintenance procedures, troubleshooting guidance, and repair or rebuild instructions for all major systems, including the powertrain, chassis, suspension, and electrical components. With over 450 pages of detailed content, including step-by-step instructions, high-resolution diagrams, and exploded views, this manual is designed to assist users in maintaining, diagnosing, and repairing their ATV, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Model Variant: Xplorer 500 Engine Displacement: 499cc Engine Type: Four-stroke, SOHC, liquid-cooled, single-cylinder Fuel Type: Unleaded Gasoline Drive Type: All-Wheel Drive (AWD) Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Codes Vin Decoder Notes: VIN decoding information not explicitly provided in product data, but typically follows industry standards for ATV manufacturers. Specific details would be in the manual. 👋 Introduction Market Position Target Audience: Owners of Polaris Sportsman 500 and Xplorer 500 ATVs from 1996-2003 seeking to perform maintenance, repairs, and diagnostics. Competitive Analysis Value Proposition: Provides professional-level repair and maintenance information, enabling users to save on repair costs and maintain their vehicle's condition. Offers comprehensive coverage for a wide range of models and years. Key Features Content Depth: In-depth and highly detailed, covering the entire vehicle from start to finish. Usability: Easy to use, with step-by-step instructions. Available for instant download. 📋 Manual Details Coverage Areas Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Specific Models Covered: Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O., Sportsman 400 ASEI, Sportsman 400 DUSE, Worker 400 (International), Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom, Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400 Desert Page Count Estimated Page Count: Approximately 450+ pages (based on typical workshop manual depth and provided index) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System Chassis And Suspension: Front Suspension and Steering, Rear Suspension, Brakes Electrical And Body: Electrical System, Body Procedures Included Maintenance: Pre-ride checks, periodic lubrication, tire maintenance, battery care, tune-ups, fluid changes, filter replacements, component cleaning and inspection Troubleshooting: Engine starting difficulties, charging system issues, ignition system problems, fuel system malfunctions, overheating, engine noises, power train issues, steering problems, frame noise, brake system faults Repair And Rebuild: Engine internal component replacement (pistons, rings, valves, camshaft, crankshaft), carburetor overhaul, clutch and drive belt service, transmission disassembly and assembly, brake caliper and master cylinder service, suspension component replacement, electrical component diagnosis and replacement Diagnostics: Cylinder leak down testing, charging system testing, ignition system testing, electronic throttle control diagnostics, carburetor performance tests Technical Depth Depth: Comprehensive; covers basic maintenance, routine servicing, advanced diagnostics, complete component overhauls, and full vehicle rebuilds. Designed for professional mechanic use. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, designed for clear viewing and printing of text and diagrams. Printable for hardcopy. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Features Searchability: Likely searchable text within the PDF for quick information retrieval. Illustrations: Includes highly detailed exploded pictures and diagrams. ⚙️ Engine Specifications Primary Engine Engine Configuration: 499cc, SOHC, 4-valve, liquid-cooled, single-cylinder Performance Horsepower Range: Typically around 30-34 HP (varies by specific year and H.O. designation). Torque Specifications: Detailed torque specifications for all engine components are provided in the manual. Fuel System Carburetor Type: Mikuni BSR42 (common for many 500cc models), specific carburetor details, cleaning, and adjustment procedures are covered. Fuel Delivery: Gravity feed with a fuel pump system. Cooling System Type: Liquid-cooled with a radiator, fan, and coolant pump. Ignition System Type: CDI (Capacitor Discharge Ignition) with detailed ignition timing and component testing. 🔧 Transmission Standard Transmission: Polaris Variable Transmission (PVT) with automatic centrifugal clutch and belt drive. Optional Transmission Options: Not applicable, PVT is standard across these models. Features Engine Braking: Integrated engine braking system for downhill control. Maintenance Fluid Type: Specific transmission fluid requirements (likely Polaris AGL or similar) are detailed in the manual. Components Drive Belt: Service, inspection, and replacement procedures for the drive belt are extensively covered, including clutch alignment and tensioning. 📐 Dimensions Exterior Wheelbase:...