This manual covers the Polaris Sportsman 400, Sportsman 500, and Xplorer 500 4x4 All-Terrain Vehicles (ATVs) produced between 1996 and 2003. These utility ATVs are renowned for their 4x4 capability, independent front suspension, and robust Polaris Variable Transmission (PVT). Designed for a variety of demanding tasks including work, recreation, hunting, and trail riding, these models offered a blend of performance and durability that made them competitive with other leading brands of their time. Their engineering focused on providing reliable power and traction for challenging terrains. This comprehensive factory service manual provides detailed information for the complete service, repair, and maintenance of these Polaris ATVs. It includes step-by-step instructions for all major systems, such as the engine, transmission, suspension, steering, brakes, and electrical components. Additionally, the manual covers routine maintenance procedures, troubleshooting guides for common issues, rebuild procedures, and critical technical specifications and torque values. This authoritative documentation is essential for owners, mechanics, and technicians to ensure the proper upkeep and longevity of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400, Sportsman 500, Xplorer 500 4x4 Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Category: Utility ATV Target User: Work, recreation, hunting, trail riding. Competitive Analysis Competitors: Yamaha Kodiak, Suzuki King Quad, Honda Foreman (during their respective production eras). Key Features Atv Features: 4x4 capability, independent front suspension (IFS) on many models, robust utility chassis, Polaris Variable Transmission (PVT). Manual Benefit: Empowers owners and technicians with the authoritative information needed for proper maintenance, repair, and longevity of these durable ATVs. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, and Maintenance Specific Models Covered: Polaris Sportsman 400 4x4, Polaris Sportsman 500 4x4, Polaris Xplorer 500 4x4 Page Count Estimated Page Count: Over 500 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Manual Description: Official factory-level repair and maintenance documentation. Language Language: English Format Format: PDF (Instant Download) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, timing, cooling, lubrication, fuel delivery, ignition systems. Transmission Drivetrain: Automatic transmission operation, maintenance, repair (PVT - Polaris Variable Transmission), final drive, differentials, driveshafts, CV joints. Suspension Steering: Front and rear suspension systems (e.g., MacPherson struts, independent suspension), shock absorbers, steering components, tie rods, universal joints. Brakes: Hydraulic brake system inspection, maintenance, caliper and master cylinder repair, bleeding procedures, disc and pad replacement. Electrical: Wiring diagrams, battery system, starter, charging system (alternator/stator), lighting, ignition switch, fuses, relays, troubleshooting electrical faults. Fuel System: Carburetor operation, tuning, cleaning, fuel pump, fuel lines, fuel tank maintenance. Body Frame: Body panel removal and installation, frame inspection, seat removal, rack systems. Cooling System: Radiator, fan, hoses, coolant specifications and change intervals. Wheels Tires: Tire pressure recommendations, wheel torque specifications. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments. Troubleshooting: Diagnostic flowcharts, common problem identification and resolution strategies, electrical diagnostic procedures. Repair: Step-by-step instructions for component removal, overhaul, replacement, and reassembly for all major systems. Rebuilds: Engine and transmission component rebuild procedures, including specifications and tolerances. Specifications Torques: Torque specifications for all fasteners, engine clearances, bearing tolerances, and other critical measurements. Technical Depth Depth: Comprehensive: Covers everything from basic rider-level maintenance to in-depth engine and transmission overhauls. Detail Level: Factory-level detail with exploded views, diagrams, and clear instructions. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable for keywords and part numbers. Print Quality Quality: High-resolution scans of original factory documentation, suitable for printing. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder Engine Type 500: Liquid-cooled, 4-stroke, SOHC, 2-valve, single-cylinder (often based on the same platform with displacement variations). Displacement 400: Approximately 375cc - 400cc (varies slightly by specific model year and sub-model) Displacement 500: Approximately 499cc - 500cc (varies slightly by specific model year and sub-model) Performance Horsepower Estimate 400: Approx. 25-30 HP Horsepower Estimate 500: Approx. 30-35 HP Torque Estimate 500: Approx. 28-32 ft-lbs Fuel System Carburetor Type: Mikuni (e.g., VM34SS or similar for 400, VM36SS or similar for 500) Fuel Type: Unleaded Gasoline (87 octane or higher) 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Automatic with High/Low Range and Reverse Drive System: Shaft Drive to Front and Rear Axles (On-Demand AWD or Full-Time 4x4) Features Clutch System: CVT belt drive system for automatic ratio adjustment. Gear Reduction: Internal gear reduction in hub carriers and differentials. 📐 Dimensions Exterior Length Estimate: Approx. 83-85 inches Width Estimate: Approx. 46-48 inches Height Estimate: Approx. 48-50 inches Weights Dry Weight Estimate: Approx. 550-650 lbs Ground Clearance Estimate: Approx. 10-11 inches Towing Capacity: Approx. 1500 lbs Payload Capacity: Approx. 200-250 lbs Cargo Rack Capacity Front: Approx. 50 lbs Rack Capacity Rear: Approx. 100 lbs 🛡️ Safety Features Ratings...