This manual covers the 400, 500, and Xplorer 500 4X4 models produced between 1996 and 2003. These all-terrain vehicles are renowned for their robust engineering, reliability, and off-road capability, making them suitable for a wide range of recreational and utility tasks. The series, a cornerstone of powersports offerings, is recognized for its comfort, utility, and performance on challenging terrain, with the Xplorer variant often tailored for more demanding trail use. This comprehensive factory service manual provides detailed information for owners and technicians. It covers all essential systems, including the engine, lubrication, fuel, exhaust, cooling, transmission, drivetrain, suspension, brakes, and electrical systems. The manual includes routine maintenance procedures, in-depth troubleshooting guides, step-by-step repair instructions for major components like the engine and transmission, and all necessary technical specifications, clearances, and torque values. This resource is designed to empower users to effectively maintain, diagnose, and repair their ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400, Sportsman 500, Xplorer 500 4X4 Codes Product Name: Polaris Sportsman 400 500 Xplorer 500 4X4 Service Manual PDF Download 👋 Introduction Market Position Target Audience: Owners of Polaris Sportsman 400, 500, and Xplorer 500 4X4 ATVs seeking to perform maintenance, repairs, and diagnostics. Competitive Analysis Value Proposition: Provides the same level of detail and accuracy as dealer-used manuals, enabling users to perform professional-level service and save on labor costs. Key Features Features: Comprehensive diagrams, step-by-step procedures, troubleshooting guides, and technical specifications. 📋 Manual Details Coverage Areas Applicable Years: 1996-2003 Page Count Estimated Page Count: Detailed, likely 500+ pages (typical for comprehensive service manuals of this era) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Download Format: RAR archive containing PDF files 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and specifications for all engine variants. Lubrication System: Oil pump, oil filter, lubrication passages, and oil change procedures. Fuel System: Carburetor (Mikuni/Keihin), fuel pump, fuel lines, fuel filter, and adjustments. Exhaust System: Exhaust pipe, muffler, heat shields, and component inspection. Cooling System: Radiator, fan, coolant, hoses, and thermostat operation. Transmission: Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, and repair. Drivetrain: Shaft drive, U-joints, differentials (front and rear), and AWD system (on applicable models). Suspension Front: A-arms, shocks, springs, wheel bearings, and steering components. Suspension Rear: Swingarm, shocks, springs, linkages, and wheel bearings. Brakes: Hydraulic disc brake systems (front and rear), brake calipers, master cylinders, hoses, and fluid specifications. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, ignition system (CDI), lighting, and switches. Wiring Diagrams: Comprehensive color-coded wiring diagrams for all electrical systems. Frame And Body: Frame inspection, body panel removal/installation, plastics, and fenders. Controls: Handlebar controls, throttle, brake lever, gear selector (if applicable), and ignition switch operation. Lighting Meters Switches: Headlights, taillights, brake lights, neutral indicator, reverse indicator, AWD indicator, and switch functions. Procedures Included Maintenance: Routine maintenance checks, lubrication points, filter replacements, and fluid changes. Troubleshooting: Detailed diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Engine Repair: Top-end rebuild (cylinder head, valves, piston), bottom-end rebuild (crankshaft, connecting rod, bearings), and full engine disassembly/assembly. Transmission Repair: PVT belt inspection and replacement, drive clutch and driven clutch service, and gearcase maintenance. Brake Service: Brake pad replacement, caliper service, bleeding procedures, and master cylinder rebuild. Suspension Adjustment: Shock preload adjustments, alignment procedures, and bearing service. Electrical Diagnostics: Testing of charging system components, ignition system, starter, and lighting circuits. Carburetor Adjustment: Idle speed, mixture adjustments, and jetting recommendations. Engine Removal Installation: Step-by-step procedures for removing and reinstalling the engine. Electric Starter: Operation, testing, and troubleshooting of the electric starter motor and associated circuitry. Charging System: Stator testing, regulator/rectifier diagnosis, and battery charging procedures. Ignition System Testing: Spark plug analysis, CDI module testing, and ignition coil diagnosis. Electric Shift Program: Diagnosis and repair of any electronic shift systems if equipped. Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Charts: Includes detailed charts correlating symptoms to potential causes and troubleshooting steps. Torque Specifications: Essential torque values for all critical fasteners and components. Clearances And Tolerances: Precise measurements for engine components, bearing play, and suspension alignments. 📊 Manual Specifications File Format File Type: PDF Paper Scan Compatibility: All Versions of Windows & Mac Required Software: WinRar / WinZip or 7-ZIP (for extraction), PDF Reader (e.g., Adobe Acrobat Reader) Print Quality Scan Quality: High-quality scans suitable for clear reading and printing. Binding Type Binding: Digital Download (Not a physical book, no binding) Paper Type Paper Type: Digital PDF (Not applicable for physical paper type) ⚙️ Engine Specifications Primary Engine Engine Types Covered: Various displacements for 400cc and 500cc class engines (e.g., 375cc, 499cc). Specific engine codes and configurations will be detailed within the manual. Performance Typical Horsepower: Ranges from approximately 25-35 HP depending on specific model and...