This comprehensive service repair manual provides detailed instructions and illustrations to guide you through the repair, maintenance, rebuilding, refurbishing, or restoration of your 1996-2003 Polaris Sportsman Xplorer 500 ATV. The manual covers all diagnostic and repair procedures, ensuring you have the necessary information to tackle any task. This manual is the same type that your local dealer uses, offering a wealth of information and expertise at your fingertips. The manual covers a wide range of models, including the Sportsman 500, Xplorer 500, Worker 500, and various special editions. The content within this service manual is extensive, covering general information, troubleshooting, lubrication, maintenance, tune-ups, engine components (top end, lower end), fuel system, cooling systems, clutch and drive belt systems, transmission, front drive system, electrical system, front suspension and steering, rear suspension, brakes, body, and even 2001-2003 specific service information. You will find a detailed index, wiring diagrams, and in-depth sections on maintenance, engine, carburetion, clutching, final drive, body and steering, transmission, brakes, and electrical components. This manual is your one-stop resource for keeping your ATV running smoothly and efficiently.

The Polaris Sportsman 400 and 500, produced between 1996 and 2003, are iconic all-terrain vehicles (ATVs) known for their ruggedness, versatility, and reliable performance. These models were popular choices for both recreational riders and utility-focused users, offering a balance of power and handling. The 400 and 500 shared a similar design, featuring a tubular steel frame, independent front suspension, and a rear swingarm with a mono-shock. The heart of these ATVs was a liquid-cooled, single-cylinder four-stroke engine, offering smooth power delivery and a comfortable ride. The Sportsman 400 was powered by a 397cc engine, while the 500 boasted a larger 499cc engine, providing more torque and top speed. Both models were available in various configurations, including standard, deluxe, and special edition versions, offering different features and aesthetics. Equipped with selectable 2WD and 4WD systems, the Sportsman 400 and 500 allowed riders to adapt to a variety of terrain conditions. The 4WD system offered enhanced traction and stability on challenging terrains, while the 2WD allowed for fuel efficiency and easier maneuverability in less demanding situations. The Sportsman models featured a spacious and comfortable seat, ergonomic controls, and an easy-to-use transmission, making them user-friendly for both novice and experienced riders. With their strong performance, durable construction, and versatile handling, the Polaris Sportsman 400 and 500 became a mainstay in the ATV market, offering a reliable and enjoyable riding experience for a wide range of users.