🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer 500 Type: All-Terrain Vehicle (ATV) Codes Vin Prefix: 4XTP 👋 Introduction Market Position Segment: Utility ATV Target Audience: Recreational riders, farmers, hunters, trail riders. Competitive Analysis Competitors: Yamaha Kodiak, Honda FourTrax, Kawasaki Bayou. Key Features Engine Size: Reputable 499cc liquid-cooled engine. Drivetrain Capability: True All-Wheel Drive (AWD) system, offering superior traction. Suspension: Independent front and rear suspension for a comfortable and capable ride. 📋 Manual Details Coverage Areas Covered Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Covered Models: Sportsman 500, Sportsman 500 RSE, Sportsman 500 HO, Xplorer 500 Page Count Estimated Pages: 300+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Top End, Bottom End, Lubrication, Cooling, Fuel System, Ignition System, Starting System Drivetrain: Transmission, Final Drive, Drive Shafts, Axles, CV Joints, AWD System (where applicable) Chassis: Frame, Suspension (Front and Rear), Steering, Wheels, Tires Electrical: Wiring Diagrams, Lighting, Battery, Charging System, Ignition, Switches, Gauges Braking: Hydraulic Brake System, Brake Calipers, Master Cylinder, Lines, Pads, Rotors Bodywork: Body Panels, Racks, Fenders, Seat Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Points Troubleshooting: Diagnostic Procedures, Symptom-Based Troubleshooting Guides, Common Issues Repair: Component Removal and Installation, Engine Rebuild, Transmission Overhaul, Suspension Repair, Electrical Component Testing and Replacement Tune Up: Carburetor Adjustment, Spark Plug Service, Ignition Timing, Valve Adjustment (if applicable) Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and torque specifications. 📊 Manual Specifications File Format Quality: High-resolution, clear text and diagrams. Searchable text for efficient navigation. Print Quality Suitability: Printable for workshop use. Designed for clarity on screen and in print. Binding Type Digital: N/A (Digital Download) Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder Displacement: 499 cc Bore X Stroke: 92 mm x 75 mm Cooling System: Liquid-cooled Performance Horsepower Est: Approximately 28-32 HP (varies by specific model year and tuning) Torque Est: Approximately 29-32 lb-ft (varies by specific model year and tuning) Fuel System Carburetor: Mikuni BNS 36 (specific model may vary, e.g., 40mm) with accelerator pump. Fuel Type: Unleaded gasoline, 87 octane minimum. Ignition System Type: CDI (Capacitor Discharge Ignition) Lubrication Oil Type: Polaris Premium 4-Stroke Synthetic Oil 0W-40 or SAE 10W-40 Motorcycle Oil (API SG or higher). Oil Capacity: Approx. 2.1 L (2.2 US qt) with filter change. 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: On-Demand True All-Wheel Drive (AWD) with 2WD selectable. Clutch System: Dual Clutch CVT with centrifugal clutch and variable drive/driven pulleys. Fluid Specifications Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant or SAE 10W-40 Motorcycle Oil. Fluid Capacity Transmission Oil Capacity: Approx. 0.5 L (0.5 US qt) 📐 Dimensions Exterior Length: Approx. 81 inches (205.7 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 48 inches (121.9 cm) Wheelbase: Approx. 50 inches (127 cm) Weights Dry Weight: Approx. 540 lbs (245 kg) Ground Clearance: Approx. 8-10 inches (20.3-25.4 cm) depending on suspension setup. Cargo Front Rack Capacity: Approx. 50 lbs (22.7 kg) Rear Rack Capacity: Approx. 100 lbs (45.4 kg) Tires Front Tire Size: 25x8-12 Rear Tire Size: 25x10-12 Wheels Bolt Pattern: 4x110 mm 🛡️ Safety Features Ratings Atv Safety: Designed for off-road use; operator must follow all safety precautions outlined in the owner's manual and recommended by Polaris. Active Features Braking System: Hydraulic disc brakes front and rear. Parking Brake: Hand-lever actuated parking brake. Passive Features Throttle Limiter: Adjustable throttle stop for novice riders. Lighting: Dual Halogen headlights, taillight/brake light. 💡 Technology Features Infotainment Gauge Cluster: Digital speedometer/odometer, neutral/reverse indicators, fuel gauge (on some models), high-beam indicator, oil light. Driver Assistance Drivetrain Control: On-Demand AWD system automatically engages front drive when rear wheels lose traction. Connectivity Accessories: Pre-wired for accessories like winches, lights, and heated grips on some models. 🔧 Maintenance Service Intervals Oil Change: Every 100 hours or 12 months. Check dipstick more frequently. Air Filter: Inspect every 20 hours; clean or replace as needed, more frequently in dusty conditions. Spark Plug: Replace every 100 hours or 12 months. Check gap at 20 hours. Valve Adjustment: Check every 100 hours or 12 months. Brake Fluid Flush: Recommended every 12 months or as needed. Fluid Specifications Coolant: Ethylene glycol-based antifreeze mixed 50/50 with distilled water. Polaris Coolant is recommended. Known Issues Common Wear Items: Drive belts (CVT), wheel bearings, ball joints, tie rod ends, brake pads. Engine Variations: Early models may have had some carburetor jetting or ignition timing differences compared to later HO (High Output) versions. Cv Boots: Susceptible to tearing in rough terrain; regular inspection is advised. 📚 Vehicle History Brand Heritage Manufacturer: Polaris Industries, founded in 1954, a major American manufacturer of...