2000-2003 Polaris Sportsman Xplorer 500, Sportsman Xplorer 400 repair manual

Product Information

Table of Contents

Chapter One: General Information

1. Manual organization
2. Notes, cautions, and warnings
3. Safety first
4. Cleaning parts
5. Handling gasoline safely
6. Service hints
7. Torque specifications
8. Fasteners
9. Lubricants
10. Threadlocking compound
11. RTV gasket sealant
12. Expendable supplies
13. Serial numbers
14. Warning and information labels
15. Basic hand tools
16. Precision measuring tools
17. Special tools
18. Fabricating tools
19. Mechanic’s tips
20. Bearing replacement
21. Seals
22. Storage

Chapter Two: Troubleshooting

1. Operating requirements
2. Troubleshooting instruments
3. Starting the engine
4. Starting difficulties
5. Engine is difficult to start
6. Engine starting system
7. Charging system
8. Ignition system
9. Electronic throttle control
10. Fuel system
11. Engine overheating
12. Engine noises
13. Cylinder leak down test
14. Power train
15. Steering
16. Frame noise
17. Brakes

Chapter Three: Lubrication, Maintenance and Tune-Up

1. Pre-ride check list
2. Tires and wheels
3. Battery
4. Battery electrical cable connectors
5. Periodic lubrication
6. Periodic maintenance
7. Unscheduled inspection and maintenance
8. Engine tune-up

Chapter Four: Engine Top End

1. Engine principles
2. Engine cooling
3. Engine lubrication
4. Servicing the engine in the frame
5. Exhaust system
6. Cylinder head cover
7. Rocker arm assembly
8. Camshaft
9. Cylinder head
10. Valves and valve components
11. Cylinder block
12. Piston and piston rings
13. Camshaft chain and sprockets
14. Break-in procedure

Chapter Five: Engine Lower End

1. Engine
2. Flywheel and stator plate
3. Recoil starter
4. Crankcase
5. Crankshaft inspection
6. Balancer shaft inspection
7. Shaft end float measurement and shim selection
8. Oil pump
9. Oil system one-way check valve
10. Break-in procedure

Chapter Six: Fuel System

1. Carburetor operation
2. Carburetor
3. Carburetor cleaning and inspection
4. Carburetor tests and adjustments
5. Throttle cable replacement
6. Starting enrichment (choke) cable
7. Fuel tank
8. Fuel shutoff valve
9. Air filter air box
10. Fuel pump

Chapter Seven: Cooling Systems

1. Polaris variable transmission (PVT) air cooling system
2. Engine cooling system
3. Safety precautions
4. Hoses and hose clamps
5. Engine gaskets/seals
6. Cooling system inspection
7. Radiator
8. Cooling fan
9. Coolant pump
10. Thermostat
11. Temperature sensors

Chapter Eight: Clutch/Drive Belt System

1. Drive unit
2. Drive pulley
3. Special tools
4. Driven pulley
5. Drive belt
6. Drive pulley
7. Driven pulley
8. Clutch outer and inner cover (all models)

Chapter Nine: Transmission

1. Transmission
2. Transmission inspection
3. Shift shafts
4. Front output shaft
5. Transmission gearcase oil seal inspection and replacement
6. Shift selector linkage

Chapter Ten: Front Drive System

1. Front hub and Hillard clutch
2. Front drive axle, boots and CV (constant velocity) joints
3. Front drive shaft
4. Front drive unit

Chapter Eleven: Electrical System

1. Basic information
2. Negative battery terminal
3. Charging system
4. Alternator stator
5. Voltage regulator/rectifier
6. Capacitor discharge ignition
7. Ignition coil
8. Ignition stator coils
9. Electric starting system
10. Starter drive gears
11. Starter solenoid
12. Lighting system
13. Electrical components
14. Switches
15. Wiring diagrams

Chapter Twelve: Front Suspension and Steering

1. Front wheel
2. Front hub
3. Front strut cartridge and spring
4. Front strut/spindle
5. Control arm
6. Handlebar
7. Tie rods
8. Steering shaft
9. Tires and wheels

Chapter Thirteen: Rear Suspension

1. Rear wheels
2. Tire changing and tire repairs
3. Shock absorber
4. Rear hub and bearing carrier
5. Rear axles
6. Upper control arm
7. Lower control arm
8. Upper and lower control arm inspection
9. Stabilizer linkage
10. Stabilizer support

Chapter Fourteen: Brakes

1. Disc brakes
2. Front brake pad replacement
3. Front caliper
4. Output shaft brake pad replacement (1996-1997 models)
5. Output shaft brake caliper (1996-1997 models)
6. Output shaft brake pad replacement (1998-on models)
7. Output shaft brake caliper (1998-on models)
8. Front master cylinder
9. Rear master cylinder
10. Brake hose replacement
11. Rear brake pedal
12. Rear brake lever (1996-1997 Sweden models)
13. Foot brake (1998-on Sweden models)
14. Brake disc
15. Bleeding the system

Chapter Fifteen: Body

1. Seat
2. Front rack and grille
3. Side panels
4. Front fender
5. Front bumper (models so equipped)
6. Radiator guard
7. Rear rack
8. Rear fender
9. Footwells
10. Rear bumper (models so equipped)

Supplement: 2001-2003 Service Information

1. Starting the engine
2. Ignition system
3. Periodic maintenance
4. Engine tune-up
5. Cylinder block
6. Piston and piston rings
7. Engine
8. Flywheel and stator plate
9. Carburetor (Sportsman 500 H.O. models)
10. Cleaning and inspection
11. Carburetor tests and adjustments
12. Drive belt
13. Driven pulley (2003 models built after 07/08/02)
14. Transmission
15. Lighting system
16. Electrical components
17. Steering shaft (2002-on models)
18. Rear hub and bearing carrier (2003 models)
19. Rear brake pad replacement (2003 models)
20. Rear calipers (2003 models)
21. Front master cylinder
22. Rear master cylinder (2003 models)
23. Rear brake disc (2003 models)
24. Brake hose replacement (2003 models)

Index

Wiring Diagrams

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