This factory service repair workshop manual provides comprehensive information for Polaris Sportsman, Xplorer, and Worker ATVs manufactured between 1996 and 2003. These utility ATVs, known for their robust engineering and reliability, are powered by liquid-cooled, 4-stroke engines ranging from 400cc to 500cc, featuring SOHC technology and automatic Variable Transmissions (PVT) with on-demand All-Wheel Drive (AWD). This manual covers a wide array of models, including various Sportsman 500, Sportsman 400, Xplorer 500, and Worker 500 variants, as well as specialized editions like the Remington Special Edition (RSE) and Ducks Unlimited Special Edition (DUSE), offering essential guidance for owners and technicians. The scope of this English-language manual is extensive, detailing everything from general information and troubleshooting to in-depth maintenance procedures, tune-ups, and complete engine and transmission rebuilds. It includes specific guidance on lubrication, fuel systems, cooling systems, clutch and drive belt systems, electrical systems, suspension, steering, and brakes. With high-quality diagrams and easy-to-read text, this manual is designed to assist users in performing routine maintenance, diagnosing and resolving issues, and conducting comprehensive repairs, ensuring the optimal performance and longevity of their ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman / Xplorer / Worker Codes Model Years Covered: 1996-2003 👋 Introduction Market Position Positioning: This manual targets owners and technicians of Polaris Sportsman, Xplorer, and Worker ATVs from 1996 to 2003, providing essential information for maintenance and repair. It serves as a critical resource for maintaining the longevity and performance of these popular utility ATVs. Key Features Features: Instant download PDF format, comprehensive coverage of multiple model years and variants, detailed diagrams and step-by-step instructions, extensive troubleshooting guide, essential maintenance schedules and fluid specifications. 📋 Manual Details Coverage Areas Covered Models: 1996 Sportsman 500, 1997 Sportsman 500, 1997 Xplorer 500, 1998 Sportsman 500, 1998 Worker 500, 1999 Sportsman 500, 1999 Worker 500, 1999 Sportsman 500 RSE, 2000 Sportsman 500, 2000 Worker 500, 2000 Sportsman 500 RSE (Remington Special Edition), 2001 Sportsman 400, 2001 Sportsman 500 DUSE, 2001 Sportsman 500 H.O., 2001 Sportsman 500 HO, 2002 Sportsman 400, 2002 Worker 400 (International), 2002 Sportsman 400 ASEI, 2002 Sportsman 400 DUSE, 2002 Sportsman 500 H.O., 2002 Worker 500 (International), 2002 Sportsman 500 RSEI, 2002 Sportsman 500 DUSE1, 2002 Sportsman 500 H.O. Desert, 2002 Sportsman 500 H.O. Freedom, 2003 Sportsman 400, 2003 Sportsman 500 H.O., 2003 Sportsman Ducks Unlimited Special Edition (DUSE), 2003 Sportsman Remington Special Edition (RSE), 2003 Sportsman 400 Desert Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Systems: General Information, Troubleshooting, Lubrication Maintenance and 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, Wiring Diagrams, Maintenance, Engine, Carburetion, Clutching, Final drive, Body and steering, Transmission, Brakes, Electrical Procedures Included Procedures: Complete disassembly and reassembly of the machine, step-by-step instructions for repairs, detailed exploded views and diagrams, diagnostics and troubleshooting, routine maintenance, tune-ups, engine rebuilds, fuel system servicing, electrical system diagnostics, suspension and steering adjustments, brake system maintenance and repair, bodywork procedures. Technical Depth Depth: Comprehensive, covering everything from basic maintenance and troubleshooting to complete engine and transmission rebuilds. Designed for both DIY users and experienced mechanics. 📊 Manual Specifications File Quality Quality: High quality diagrams and easy-to-read text sections. Print Ability Printability: All pages are printable. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC Engine Displacement Range: 400cc - 500cc Fuel System Carburetion: Mikuni carburetor (specific model varies by year and engine size, likely a VM36 or similar for 500cc models, and smaller for 400cc models). Manual covers carburetor removal, cleaning, adjustment, and troubleshooting. 🔧 Transmission Standard Type: Automatic Polaris Variable Transmission (PVT) with Polaris on-demand All-Wheel Drive (AWD). Features Transmission Features: Includes High/Low range, Neutral, Reverse. Manual covers clutch inspection, maintenance, belt replacement, and drive system components. 📐 Dimensions Weights Dry Weight Approx: Varies by model, generally in the range of 500-650 lbs (227-295 kg). 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear (typically dual front discs, single rear disc). Manual covers brake caliper service, fluid replacement, bleeding, and pad replacement. 💡 Technology Features Infotainment Features: Basic for its era, primarily focused on functionality. Instrumentation typically includes speedometer, odometer, trip meter, and indicator lights for AWD, oil pressure, and gear selection. No advanced infotainment systems. Driver Assistance Features: Polaris on-demand All-Wheel Drive (AWD) system is a key technological feature, automatically engaging front wheels when rear wheels lose traction. Electronic fuel gauges or indicators might be present on some higher-trim models. 🔧 Maintenance Service Intervals Intervals: The manual provides detailed recommended service intervals for oil changes, filter replacements, spark plug checks, valve adjustments, belt inspections, brake service, and other critical maintenance tasks....