1996-2003 Polaris Sportsman 400, 500 & Xplorer 500 Service Manual
Covers Polaris Sportsman 400, 500, and Xplorer 500 models from 1996-2003. Includes detailed procedures for engine, transmission, and chassis systems. Ref: W969244, W97CH50A, S97S0AE, W97CD50A
Manual Preview
Sample pages from the 1996-2003 Polaris Sportsman 400, 500 & Xplorer 500 Service Manual manual
Purchase & Download
Polaris Models Covered & Key Technical Specifications
Models: Polaris Sportsman 400, Polaris Sportsman 500, Xplorer 500
Sub-models / Variants: U.S. (United States), Sweden, Remington Special Edition (RSE)
Build Years: 1996–2003
Serial Numbers: W969244, W97CH50A, S97750AE, W97CD50A, W98CH50AB, W98CH50AC, W98CH50AD, W98CH50AE, W98CH50AF, S98CH50E, S98CH50EB, A99CH50AA, A99CH50AB, A99CH50EA, A99CH50EB, A99CH50AC, A00CH50A, A00CH50AB, A00CH50EA, A00CH50EB, A00CH50AC
Technical Data:
- Engine Displacement: 400 cc, 500 cc
- Transmission: Polaris Variable Transmission (PVT)
- Coolant System Capacity: Approx. 2.16 L (2.25 U.S. qts.)
- Idle Speed: 1000–1400 rpm (variable by model/year)
- Tire Inflation Pressure: 34.5 kPa (5 PSI) front and rear
- Oil Pressure: 138 kPa (20 psi) standard at 5500 rpm
Polaris Manual Features & Content Preview
Technical Scope and Coverage
- Covers 1996–2003 Polaris Sportsman 400, 500 and Xplorer 500 including U.S., Sweden, and Remington Special Edition variants
- Original OEM publication, 505-page technical service manual
- Contains 90 numbered figures including system exploded views, wiring schematics, and mechanical assembly diagrams
- Downloads to your account within seconds of checkout
- Indexed PDF search covers every chapter and appendix
- Detailed torque tables for crankcase, cylinder head, and suspension components
- Includes specialized troubleshooting flow charts for fuel, electrical, and cooling systems
- Comprehensive specification tables covering fluid capacities, timing, and valve clearances
- This 505-page reference remains the primary OEM documentation for the 1996–2003 Polaris Sportsman 400, 500 and Xplorer 500 series maintenance and technical review
Manual Organization and System Coverage
The 1996–2003 Polaris Sportsman 400, 500 and Xplorer 500 service manual is structured to provide clear technical context for both experienced mechanics and enthusiasts performing vehicle maintenance. The initial chapters detail critical safety procedures, standard shop tool selection, and precision measuring techniques using micrometers and dial gauges, while subsequent sections focus on the disassembly, assembly, and inspection of core components like the engine top end, lower end, clutch, and front drive systems. A comprehensive service manual approach is utilized, weaving technical theory with model-specific data tables to define proper system performance.
Specification Highlights and Reference Values
Technical data provided includes specific torque settings for critical fasteners, such as the cylinder head cover at 8.2 Nm (72 in.-lb.) and crankshaft drain plugs at 19 Nm (14 ft.-lb.). Cooling system parameters document a 50:50 ethylene glycol-based mixture for aluminum radiators. Electrical specifications cover stator coil resistances, such as the 1999-on exciter coil resistance of 1.6 ohms between red and green terminals. Fluid capacity data lists 1.89 liters for engine oil and 75 cc for front hub oil.
Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions.
Manual FAQ, Purchase & Download Details
Customer Reviews
Read what our customers say about this Polaris ATV manual and share your own experience.