🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer 500 Model Variant: Sportsman 500, Xplorer 500, Worker 500, Sportsman 500 RSE, Sportsman 500 DUSE, Sportsman 500 H.O. Codes Chassis Code: Not specified, but consistent within model years Engine Code: Likely variations of the Fuji-Robin or Polaris manufactured 499cc 4-stroke OHV single-cylinder engine, specific codes not provided. 👋 Introduction Market Position Purpose: To provide comprehensive service and repair information for the Polaris Sportsman Xplorer 500 ATV, enabling owners and technicians to maintain and repair the vehicle effectively. Key Features Content Advantage: High-resolution diagrams, easy-to-read text, step-by-step instructions, designed for both DIY and professional users. Value Proposition Cost Savings: Inexpensive way to keep the vehicle working properly, avoiding dealer labor costs for repairs and maintenance. Dealer Equivalence Professional Standard: Equivalent to the service manual used by local dealers. 📋 Manual Details Coverage Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Models Covered Detail: 1996 Sportsman 500; 1997 Sportsman 500, Xplorer 500; 1998 Sportsman 500, Worker 500; 1999 Sportsman 500, Worker 500, Sportsman 500 RSE; 2000 Sportsman 500, Worker 500, Sportsman 500 RSE (Remington Special Edition); 2001 Sportsman 400, Sportsman 500 DUSE, Sportsman 500 H.O.; 2002 Sportsman 400, Worker 400 (International), Sportsman 400 ASEI, Sportsman 400 DUSE, Sportsman 500 H.O., Worker 500 (International), Sportsman 500 RSEl, Sportsman 500 DUSE1, Sportsman 500 H.O. Desert, Sportsman 500 H.O. Freedom; 2003 Sportsman 400, Sportsman 500 H.O., Sportsman Ducks Unlimited Special Edition (DUSE), Sportsman Remington Special Edition (RSE), Sportsman 400 Desert. Format File Format: PDF Delivery Method: Instant Download Compatibility: All PC based Windows operating systems & Mac Requirements: Adobe PDF Reader & WinZip Language Language: English Manual Type Type: Service Repair Manual Quality Print Quality: High resolution, excellent print quality for needed pages 📖 Manual Coverage Systems Covered Primary Systems: General Information, Troubleshooting, Lubrication, Maintenance, Tune-Up, Engine Top End, Engine Lower End, Fuel System, Cooling Systems, Clutch/Drive Belt System, Transmission, Front Drive System, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, Body. Additional Systems: 2001-2003 Specific Service Information, Wiring Diagrams. Procedures Included Maintenance Procedures: Scheduled maintenance, lubrication, fluid changes, filter replacements, tune-ups. Repair Procedures: Step-by-step instructions for all major repair areas, engine rebuilds, drivetrain component service, suspension and steering repairs, brake system service, electrical diagnostics and repair, body panel removal and installation. Diagnostic Procedures: Troubleshooting guides for common and complex issues, diagnostic flowcharts. Technical Depth Depth: Comprehensive; suitable for DIY enthusiasts and professional mechanics. Covers detailed disassembly, reassembly, and adjustment procedures. 📊 Manual Specifications File Characteristics Searchable Text: Implied by PDF format and high quality, likely includes searchable text. Physical Attributes Binding Type: Digital PDF (printable to CD or individual pages) Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 4-stroke, Overhead Valve (OHV) Displacement: 499cc (for 500 models); 400cc (for 400 models) Bore X Stroke: Not specified, but typical for the era and displacement range. Cooling System: Liquid-cooled (for most 500 models and some 400s) Performance Horsepower: Typically in the range of 25-30 HP, specific figures vary by model year and tuning. Torque: Not specified, but designed for low-end torque for utility and trail riding. Fuel System Carburetion: Mikuni Carburetor (specific model not listed, likely BSR series for 500cc). The manual covers carburetion for maintenance and tuning. Fuel Type: Unleaded gasoline Fuel Capacity: Typically around 3.2 gallons (12.1 liters), varies slightly by year/model. Ignition System: CDI (Capacitor Discharge Ignition), electronic ignition. 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) with centrifugal clutch and belt drive. Optional Type: N/A Features Gear Selection: High, Low, Neutral, Reverse. Drive System: Shaft drive to rear axle, with selectable 2WD/4WD and front differential engagement (On-Demand AWD). Fluid Specifications Transmission Oil Type: Polaris Premium 2-Cycle Lubricant (for pre-mix models) or specific PVT fluid/oil as per manual, typically SAE 20W-50 for engine/transmission if combined, or specific PVT fluid. The manual will detail exact requirements. 📐 Dimensions Exterior Length: Approximately 81 inches (205.7 cm) for Sportsman 500 models, may vary slightly. Width: Approximately 46 inches (116.8 cm) for Sportsman 500 models, may vary slightly. Height: Approximately 47 inches (119.4 cm) for Sportsman 500 models, may vary slightly. Weights Dry Weight: Around 500-550 lbs (227-250 kg), depending on exact model and features. Towing Capacity: Typically 1,500 lbs (680 kg). Dimensions Ground Clearance: Approximately 10.5 inches (26.7 cm). Wheelbase: Approximately 50.5 inches (128.3 cm). 🛡️ Safety Features Features Braking System: Hydraulic disc brakes on all wheels (dual front, single rear). Manual covers brake system maintenance and repair. Tire Specifications: Front: 25x8-12, Rear: 25x10-12 (common, may vary by trim/year). Manual will specify tire pressure and maintenance. Rollover Protection: ATVs are not equipped with integrated rollover protection systems like ROPS found on UTVs or other vehicles. Operation requires rider skill and adherence to safety guidelines. 💡 Technology Features Infotainment System: N/A - basic ATV with focus on function, not infotainment....