The Sportsman Xplorer Worker, available in 400 and 500 model variants, represents a robust utility All-Terrain Vehicle (ATV) designed for professional users, landowners, hunters, and recreational riders who demand reliable performance and substantial hauling capabilities. Produced between 1996 and 2003, these ATVs are distinguished by their focus on work, featuring strong towing and cargo capacity, and a durable construction built for rugged use across diverse terrains. Engineered with a strong emphasis on utility, the Sportsman Xplorer Worker series offers dependable operation, making it a capable partner for demanding tasks and challenging environments. This comprehensive workshop service repair manual, written in English, provides detailed guidance for the maintenance and repair of the Sportsman Xplorer Worker models from 1996 to 2003. It covers all essential systems, including the engine, powertrain, chassis, electrical, and fuel systems, offering in-depth procedures for regular maintenance, component overhauls, and troubleshooting. With clear instructions, technical specifications, and detailed illustrations, this manual serves as an invaluable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer Worker Model Variant: 400, 500 Codes Vin Prefix: 4XTC (Polaris ATV) 👋 Introduction Market Position Segment: Utility ATV (All Terrain Vehicle) Target User: Professional users, landowners, hunters, recreational riders requiring robust performance and utility Competitive Analysis Competitors: Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou, Suzuki King Quad Key Features Utility Focus: Emphasis on work capability, towing, hauling, and reliable operation in diverse terrains Durability: Designed for rugged use and extended operational life 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Page Count Estimated Page Count: Approx. 300-500 pages (typical for this era and scope) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drive Systems (AWD/2WD), Differentials, Drive Shafts, CV Joints Chassis: Frame, Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Wheels, Tires Electrical: Ignition System, Charging System (Stator, Rectifier/Regulator, Battery), Starting System (Starter Motor, Solenoid), Lighting, Instruments, Wiring Diagrams, Switches, Controls Fuel System: Carburetor(s) (Maintenance, Adjustment, Rebuild), Fuel Pump, Fuel Lines, Fuel Tank Cooling System: Radiator, Fan, Hoses, Thermostat, Coolant Exhaust System: Exhaust Pipes, Muffler, Heat Shields Body And Trim: Body Panels, Fenders, Racks, Seat, Handlebars, Decals Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, lubrication points, battery care, tire pressure checks Repair: Engine overhaul, transmission repair, carburetor rebuild, brake system service, suspension component replacement, electrical component troubleshooting and repair Troubleshooting: Diagnostic charts for common problems (starting issues, poor performance, electrical faults, etc.) Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters Diagrams: Detailed exploded views, wiring diagrams, service illustrations Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and component rebuilds) 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable pages Print Quality Printability: Designed for clear printing of text and diagrams Binding Type Binding For Download: N/A (Digital PDF) Paper Type Paper Type For Download: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder Engine Type 500: 4-stroke, SOHC, 2-valve, Liquid-Cooled, Single Cylinder Displacement Displacement 400: Approximately 375cc - 400cc (exact varies by specific sub-model/year) Displacement 500: Approximately 499cc - 500cc (exact varies by specific sub-model/year) Performance Horsepower 400: Estimated 20-25 HP (varies by year/tuning) Horsepower 500: Estimated 28-32 HP (varies by year/tuning) Torque 400: Estimated 22-25 lb-ft (varies by year/tuning) Torque 500: Estimated 28-32 lb-ft (varies by year/tuning) Fuel System Carburetor Type: Mikuni or Keihin Single Carburetor (specific model dependent) Fuel Type: Unleaded Gasoline Lubrication Oil Type: SAE 20W-50 or 10W-40 Motorcycle/ATV Oil (refer to manual for exact specification) Cooling System Coolant Type: Ethylene Glycol-based Antifreeze (50/50 mix with distilled water recommended) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) with Hi/Lo Range and Reverse Optional Optional Transmission Types: N/A (CVT was standard across these models) Features Drive Selection: On-Demand All-Wheel Drive (AWD) / 2WD selectable Final Drive: Shaft Drive (to rear differential and front wheels) Fluid Specifications Transmission Fluid Type: Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent (check manual for specific part number) 📐 Dimensions Exterior Length: Approx. 80-85 inches (203-216 cm) Width: Approx. 45-48 inches (114-122 cm) Height: Approx. 46-48 inches (117-122 cm) Weights Dry Weight: Approx. 550-600 lbs (249-272 kg) Ground Clearance: Approx. 8-11 inches (20-28 cm) Cargo Rack Capacity Front: Approx. 90 lbs (40 kg) Rack Capacity Rear: Approx. 200 lbs (90 kg) Towing Capacity: Approx. 1,225 - 1,500 lbs (556 - 680 kg) Tires Front Tire Size: 25x8-12 or 26x8-12 (typical) Rear Tire Size: 25x11-12 or 26x11-12 (typical) Tire Pressure Front: Typically 5-7 PSI (refer to manual for exact specs) Tire Pressure Rear: Typically 5-7 PSI (refer to manual for exact specs) 🛡️ Safety Features Ratings Atv Safety Standards: Compliant with ANSI/SVIA...