The Polaris Sportsman Xplorer, offered in 400 4WD and 500 4WD variants, represents a robust line of All-Terrain Vehicles (ATVs) produced between 2000 and 2003. Renowned for its true 4WD system, independent front suspension, and powerful engines for their class, these ATVs are engineered for versatility and reliable off-road performance. These ATVs are designed to meet ANSI/SVIA standards, offering a comfortable ride and intuitive controls suitable for a wide range of utility and recreational tasks. This comprehensive Factory Workshop Service Repair Manual provides detailed information essential for the maintenance and repair of your Polaris Sportsman Xplorer ATV. Covering all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system, this manual offers step-by-step instructions, diagnostic procedures, and precise technical specifications. With over 500 pages of factory-level detail, including exploded views and diagrams, it is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer Model Variant: 400 4WD, 500 4WD Model Years Covered: 2000, 2001, 2002, 2003 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Segment: Utility ATV segment, known for versatility and off-road capability. Competitive Analysis Competitors: Yamaha Grizzly, Honda Foreman/Rancher, Suzuki King Quad. Key Features Features: True 4WD system, independent front suspension (IFS), powerful engines for their class, robust utility features. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive repair and service information for Polaris Sportsman Xplorer 400/500 4WD ATVs Page Count Estimated Page Count: 500+ Manual Type Type: Factory Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, inspection, repair, troubleshooting, specifications for both 400cc and 500cc engines. Transmission: PVT (Polaris Variable Transmission) system maintenance, belt inspection, clutch service, gearbox troubleshooting. Drivetrain: Front and rear drive components, CV joints, drive shafts, differential maintenance and repair. Suspension: Front and rear suspension systems, shock absorbers, A-arms, bushings, wheel bearings, alignment specifications. Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pad replacement, bleeding procedures, rotor specifications. Electrical System: Wiring diagrams, battery, starter, alternator, ignition system, lighting, diagnostics for electrical faults. Fuel System: Carburetor(s) (specific to engine size), fuel pump, fuel lines, fuel tank maintenance. Cooling System: Radiator, fan, coolant, thermostat, hoses, troubleshooting for overheating. Chassis And Body: Frame inspection, body panel removal and installation, seat, handle bar, rack maintenance. Procedures Included Maintenance: Regular service intervals, oil changes, filter replacements, lubrication points, spark plug service. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Repair: Detailed step-by-step repair instructions for all major components and systems. Disassembly Assembly: Complete procedures for taking apart and reassembling all vehicle systems. Diagnostics: Schematics, test procedures, component testing, fault code interpretation (if applicable). Technical Depth Depth: Factory-level detail suitable for professional technicians and experienced DIY mechanics. Specifications: Torque values, clearances, fluid capacities, electrical resistance, voltage specifications. Diagrams Illustrations: Exploded views, detailed diagrams, wiring schematics, and step-by-step illustrations. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text content within the PDF for efficient information retrieval. Print Quality Quality: High-resolution digital scans, ensuring clarity of text and images. Binding Type Delivery Method: Digital Download Paper Type Material Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, liquid-cooled, SOHC, single-cylinder Engine Displacement 400: Approx. 375cc - 400cc (Specific variant dependent) Engine Type 500: 4-stroke, liquid-cooled, SOHC, single-cylinder Engine Displacement 500: Approx. 499cc Performance Horsepower Estimated 400: Approx. 20-25 HP (Varies by exact model year and tuning) Horsepower Estimated 500: Approx. 28-32 HP (Varies by exact model year and tuning) Fuel System Fuel Delivery 400: Carburetor (e.g., Mikuni BSR32) Fuel Delivery 500: Carburetor (e.g., Mikuni BSR34) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Type: Automatic (Polaris Variable Transmission - PVT) Gearing: High, Low, Neutral, Reverse Features Drive System: Shaft drive, On-Demand True All-Wheel Drive (AWD) 📐 Dimensions Exterior Length: Approx. 83-85 inches (Varies slightly by year/model) Width: Approx. 46-48 inches Height: Approx. 48-50 inches Weights Dry Weight 400: Approx. 600-620 lbs Dry Weight 500: Approx. 620-640 lbs Towing Capacity: 1500 lbs Rack Capacity Front: 100 lbs Rack Capacity Rear: 200 lbs 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI/SVIA standards. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Lighting: Dual headlights, tail light/brake light. Ergonomics: Comfortable seating, ergonomic handlebars, intuitive controls. 💡 Technology Features Infotainment Features: Basic functionality, focus on utility and performance rather than advanced tech. Includes analog gauges (speedometer, odometer, fuel, temp), 12V accessory outlet. Driver Assistance Features: N/A (No electronic driver aids like traction control or ABS typically found on these models). Connectivity Features: N/A (No modern connectivity features). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 100 hours or annually, whichever comes first. Spark Plug Replacement: Check and gap every 100 hours, replace as needed. Air Filter Cleaning: Check...