This manual provides comprehensive service and repair information for the Sportsman Xplorer 400 and 500 All-Terrain Vehicles (ATVs) produced between 1996 and 2003. These models, including various sub-models such as 4x4, Duse, HO, and RSE, are known for their robust engineering and versatility in both utility and recreational applications. A manufacturer with a strong heritage dating back to 1954, has consistently delivered innovative off-road vehicles, and the Sportsman line represents a significant part of their ATV development history, offering reliable performance and capable 4x4 systems. This Factory Workshop Manual is designed to assist both do-it-yourself enthusiasts and professional mechanics in maintaining and repairing these ATVs. It covers a wide array of critical systems, including the engine, fuel system, transmission, electrical system, and chassis, detailing everything from routine maintenance procedures and fluid specifications to complete component overhauls and troubleshooting. With step-by-step instructions, hundreds of detailed illustrations, and diagrams, this manual ensures owners and technicians have the authoritative information needed to keep their Sportsman Xplorer operating at peak performance, offering the same level of detail found in factory dealership resources. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Xplorer 400/500 Sub Model: 400, 500, 4x4, Duse, HO, RSE Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Vehicle Type: All-Terrain Vehicle (ATV) Product Type: Factory Workshop Manual 👋 Introduction Market Position Target Audience: Do-it-yourself (DIY) enthusiasts and experienced professional mechanics. Competitive Analysis Value Proposition: Provides the same authoritative repair and service information used by authorized Polaris dealerships, offering significant cost savings over dealer-specific service. Key Features Key Features: Step-by-step instructions, hundreds of detailed illustrations, printable pages, instant download for immediate use. 📋 Manual Details Coverage Areas Covered Models: 1996 Polaris Sportsman 400 4x4, 1996 Polaris Sportsman 4x4, 1996 Polaris Sportsman 500 4x4, 1996 Polaris Sportsman 500, 1996 Polaris Xplorer 300, 1996 Polaris Xplorer 400, 1997 Polaris Sportsman 400 4x4, 1997 Polaris Sportsman 4x4, 1997 Polaris Sportsman 500 4x4, 1997 Polaris Sportsman 500, 1997 Polaris Xplorer 400, 1997 Polaris Xplorer 500 4x4, 1997 Polaris Xplorer 500, 1998 Polaris Sportsman 500 4x4, 1998 Polaris Sportsman 500, 1998 Polaris Xplorer 400, 1999 Polaris Sportsman 500 4x4, 2000 Polaris Sportsman 500 4x4, 2001 Polaris Sportsman 400 4x4, 2001 Polaris Sportsman 500 Duse 4x4, 2001 Polaris Sportsman 500 HO 4x4, 2002 Polaris Sportsman 400 4x4, 2002 Polaris Sportsman 500 Duse 4x4, 2002 Polaris Sportsman 500 HO 4x4, 2002 Polaris Sportsman 500 RSE 4x4, 2003 Polaris Sportsman 400 4x4, 2003 Polaris Sportsman 500 HO 4x4 Page Count Estimated Page Count: Extensive (typical for factory workshop manuals covering multiple years/models, likely 800+ pages) Manual Type Manual Type: Factory Workshop / Service / Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Covered Systems: Engine (internal components, timing, carburetion/fuel injection), Fuel System, Lubrication System, Cooling System, Transmission, Drive Chain & Sprockets, Steering System, Suspension (Shocks), Electrical System (wiring diagrams, ignition, lighting, starter), Braking System, Chassis, Bodywork, Intake & Exhaust Procedures Included Included Procedures: Routine Maintenance, Engine Removal and Installation, Complete Engine Rebuilds, Fuel System Service (carburetor/injector cleaning and adjustment), Cooling System Flush and Fill, Transmission Overhaul, Drive Chain Adjustment and Replacement, Steering Component Service, Shock Absorber Service, Electrical System Troubleshooting, Wiring Harness Repair, Body Panel Removal and Installation, Suspension Adjustment and Repair, Brake System Maintenance and Bleeding Technical Depth Technical Depth: Comprehensive (from basic maintenance to full component overhaul and diagnostics) 📊 Manual Specifications File Format File Format Details: PDF. Searchable text, high-resolution illustrations. All pages printable. Print Quality Illustration Quality: Detailed illustrations, diagrams, and exploded views. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Compatibility Software Compatibility: Compatible with all versions of Windows & Mac. Requires Adobe PDF Reader. ⚙️ Engine Specifications Primary Engine 400 Engine Type 400: Liquid-cooled, 2-stroke, single-cylinder (typically Polaris Liberty engine architecture) Primary Engine 500 Engine Type 500: Liquid-cooled, 4-stroke, SOHC, V-twin (typically Polaris Prostar V-Twin engine architecture) Displacement 400 Displacement 400Cc: Approx. 398cc (actual displacement varies slightly by year and specific variant) Displacement 500 Displacement 500Cc: Approx. 499cc - 500cc (actual displacement varies slightly by year and specific variant, e.g., HO variants) Performance 400 Horsepower 400: Typically in the range of 30-35 HP (Horsepower) Performance 500 Horsepower 500: Typically in the range of 34-40 HP (Horsepower), with HO models offering slightly more. Fuel System Fuel Delivery 400: Carbureted (e.g., Mikuni VM series) Fuel Delivery 500: Carbureted (e.g., Keihin CV series) for earlier models, potential for early fuel injection systems in later 'HO' or specialized variants covered within the model range. Cooling System Cooling Type: Liquid-cooled Lubrication System Lubrication Type: Wet Sump 🔧 Transmission Primary Transmission Transmission Type: Automatic (CVT - Continuously Variable Transmission) with Polaris Variable Transmission (PVT) Drive System Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Gear Reduction Gear Reduction Units: High and Low range, Reverse...