This comprehensive Polaris Sportsman Xplorer 500 ATV Workshop Service Repair Manual provides detailed instructions and illustrations for servicing and repairing your ATV. It covers all models from 1996 to 2003, including the Sportsman 500, Xplorer 500, Worker 500, and various special editions. The manual is organized into chapters that cover every aspect of your ATV, starting with general information about safety, tools, and lubricants. It then guides you through troubleshooting procedures, routine maintenance tasks, and detailed engine and transmission rebuilds. You'll find step-by-step instructions for everything from replacing a tire to overhauling the engine, all accompanied by clear, detailed illustrations. Specific topics covered include: * **General Information:** Safety, tools, lubrication, and maintenance tips. * **Troubleshooting:** Identifying and resolving problems with your ATV. * **Lubrication and Maintenance:** Routine maintenance procedures and schedules. * **Engine Top End:** Disassembling, inspecting, and rebuilding the cylinder head and valve train. * **Engine Lower End:** Disassembling, inspecting, and rebuilding the crankshaft, connecting rods, and other components. * **Fuel System:** Servicing the carburetor, fuel lines, and fuel tank. * **Cooling System:** Inspecting and repairing the cooling system, including the radiator, fan, and thermostat. * **Clutch/Drive Belt System:** Servicing the drive belt, drive pulley, and driven pulley. * **Transmission:** Disassembling, inspecting, and repairing the transmission. * **Front Drive System:** Inspecting and repairing the front axles, hubs, and CV joints. * **Electrical System:** Diagnosing and repairing the charging system, ignition system, and lighting system. * **Front Suspension and Steering:** Servicing the front suspension, steering system, and handlebars. * **Rear Suspension:** Servicing the rear suspension, axles, and shocks. * **Brakes:** Replacing brake pads, rebuilding calipers, and bleeding the brake system. * **Body:** Removing, inspecting, and replacing body panels, seats, and racks. With this manual, you'll have everything you need to keep your Polaris Sportsman Xplorer 500 ATV running smoothly and reliably. You'll save money on repair bills and gain the satisfaction of knowing you can handle any repair yourself.

The Polaris Sportsman Xplorer 500 ATV, produced between 1996 and 2003, was a popular choice for recreational riders seeking a reliable and capable all-terrain vehicle. Sporting a 499cc, air-cooled, single-cylinder engine, the Sportsman Xplorer 500 offered a healthy balance of power and fuel efficiency. The engine was known for its smooth operation and strong torque, allowing the ATV to confidently navigate challenging terrain and haul cargo. The machine's rugged design, featuring a durable steel frame and independent front and rear suspension, provided excellent stability and comfort during rides. The Sportsman Xplorer 500 was also equipped with a standard alternator, allowing riders to enjoy the convenience of powering accessories such as lights or winches. The Sportsman Xplorer 500 was designed to be versatile and accommodating, with features like a spacious cargo box for hauling gear and a comfortable rider-centric seating position. The ATV came with a manual transmission, offering riders control over gear selection, ensuring optimal performance in different riding situations. However, the Xplorer 500 also shared some shortcomings with other Polaris models of the era, including a somewhat dated design and a lack of advanced features like electronic fuel injection. Despite these minor drawbacks, the Xplorer 500 remained a popular choice for its reliability, practicality, and capable off-road performance. It was a workhorse ATV well-suited for a variety of tasks, from recreational trail riding to utility work and light-duty hauling.