This comprehensive service and repair manual provides detailed instructions and diagrams for maintaining, servicing, diagnosing, and repairing your Polaris Sportsman 400, 500, and Xplorer 500 4x4 ATVs, covering models from 1996 to 2003. It's the same manual used by technicians at authorized Polaris dealerships, offering you a professional-level resource for all your ATV needs. The manual covers a wide range of topics, including: * **General Information:** Essential introductory material, providing you with an overview of your ATV and its components. * **Frame, Body Panels, and Exhaust System:** Detailed information on these critical structural and aesthetic elements, covering everything from assembly to troubleshooting. * **Maintenance:** Routine maintenance procedures for keeping your ATV in top condition, including oil changes, filter replacements, and other essential tasks. * **Lubrication System:** An in-depth guide to the lubrication system, covering components, operation, and maintenance procedures. * **Fuel System:** Explore the intricacies of your ATV's fuel system, from the fuel tank to the carburetor, with instructions for troubleshooting and repair. * **Engine Removal and Installation:** Detailed instructions for safely removing and reinstalling the engine, covering every step of the process. * **Cylinder Head and Valve System:** Comprehensive information on the cylinder head and valve system, including detailed diagrams and maintenance procedures. * **Cylinder and Piston Assembly:** A comprehensive guide to the cylinder and piston, covering assembly, disassembly, and troubleshooting. * **Clutch and Gearshift Linkage:** Explore the workings of the clutch and gearshift linkage, with instructions for maintenance and repair. * **Alternator and Starter Clutch:** Learn about the alternator and starter clutch, understanding their functions and how to diagnose and repair any problems. * **Crankcase, Transmission, and Crankshaft:** An in-depth guide to these critical components, covering maintenance, repair, and troubleshooting. * **Front Wheel, Suspension, and Steering:** Detailed information on the front wheel, suspension, and steering system, covering assembly, adjustment, and repair. * **Rear Wheel and Suspension:** A comprehensive guide to the rear wheel and suspension, covering every aspect from maintenance to troubleshooting. * **Hydraulic Disc Brakes:** Learn about the hydraulic disc brakes, covering operation, maintenance, and repair procedures. * **Battery:** This section covers the battery, its function, maintenance, and troubleshooting. * **Charging System:** An in-depth guide to the charging system, covering components, operation, and repair. * **Ignition System:** Explore the ignition system in detail, covering functions, maintenance, and troubleshooting. * **Electric Starter:** Learn about the electric starter, its components, operation, and how to diagnose and fix problems. * **Lights, Meters, and Switches:** A comprehensive explanation of the lighting system, meters, and switches, covering troubleshooting and repair. * **Electric Shift Program:** For models with electric shift, this section provides detailed information on the system, including operation, maintenance, and troubleshooting. * **Wiring Diagram:** A detailed wiring diagram that helps you understand the electrical system of your ATV, making diagnostics and repairs easier. * **Technical Features:** An overview of the technical specifications and features of the specific ATV models covered. * **Troubleshooting:** A valuable resource for diagnosing and fixing problems with your ATV, offering step-by-step guidance and troubleshooting charts. This service manual is an indispensable resource for anyone who wants to maintain, service, or repair their Polaris Sportsman 400, 500, or Xplorer 500 4x4 ATV. Its professional-level content empowers you to handle any job with confidence, saving you time and money.

The Polaris Sportsman 400, 500, and Xplorer 500 4x4 are a trio of popular utility ATVs renowned for their ruggedness, versatility, and reliable performance. These machines, manufactured by Polaris Industries, boast a blend of power, durability, and user-friendly features that have made them a favorite among riders seeking adventure and functionality. The Sportsman 400, powered by a 399cc single-cylinder engine, offers a balance of power and fuel efficiency, making it ideal for work and recreation. The Sportsman 500, equipped with a 499cc single-cylinder engine, delivers increased power and torque, enabling it to tackle tougher terrains and heavier loads. The Xplorer 500 4x4, sharing the same engine as the Sportsman 500, incorporates a four-wheel drive system, providing exceptional traction and stability for challenging off-road adventures. These ATVs feature a robust, durable frame, a comfortable seat, and an intuitive control layout, enhancing rider comfort and control. They also offer a wide range of accessories, allowing customization for specific needs and preferences. Beyond their core features, these Polaris ATVs are known for their reliability, longevity, and ease of maintenance. They are equipped with proven components and a well-designed construction, ensuring years of dependable service. The Polaris Sportsman 400, 500, and Xplorer 500 4x4 are more than just machines; they are companions for work, adventure, and recreation. Their versatile nature allows them to excel in a wide array of activities, from hauling firewood and clearing trails to exploring remote wilderness and navigating challenging terrain. Whether you're a seasoned off-road enthusiast, a working professional, or simply looking for an exciting way to enjoy the outdoors, these Polaris ATVs provide the power, durability, and versatility to meet your needs and exceed your expectations.