1996-2003 Polaris Sportsman 400, 500, Xplorer 500 manual

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Polaris 1996-2003 Polaris Sportsman 400, 500, Xplorer 500 manual - Technical Specifications

  • File Size: 50.76 MB
  • File Type: ZIP
  • Language: English
  • Printable: Yes
  • Estimated Download Time: 1.04 Minutes
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Polaris Models and Parts Covered in this ATV Manual

  • Sportsman 400
  • 500
  • Xplorer 500 / Polaris Industries Inc™
  • 1996 Polaris Sportsman 400L
  • 1996-1999 Polaris Sportsman 500
  • 1997 Polaris Xplorer 500
  • 2000-2002 Polaris Xplorer 500 4x4
  • 2000-2003 Polaris Sportsman 400
  • 2000-2003 Polaris Sportsman 500 HO (High Output)
  • 2001-2003 Polaris Sportsman 500 DUSE (Ducks Unlimited Special Edition)
  • 2001-2003 Polaris Sportsman 500 RSE (Remington Special Edition)

Production/model years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Polaris 1996-2003 Polaris Sportsman 400, 500, Xplorer 500 manual - Complete Manual Information

Table of Contents

General Information

  • Identification
  • Safety
  • Maintenance Schedule

Engine

  • Specifications
  • Engine Removal
  • Engine Disassembly
  • Engine Inspection
  • Engine Assembly
  • Engine Installation
  • Cooling System
  • Lubrication System

Fuel System

  • Carburetor
  • Fuel Pump
  • Fuel Tank
  • Fuel Lines
  • Fuel Filter

Electrical System

  • Battery
  • Charging System
  • Ignition System
  • Lighting System
  • Wiring Diagram

Transmission

  • Gear Shifting Mechanism
  • Drive Belt
  • Clutch
  • Gearbox
  • Transmission Troubleshooting

Drivetrain

  • Front Drive
  • Rear Drive
  • Axles
  • Differentials

Suspension

  • Front Suspension
  • Rear Suspension
  • Shock Absorbers

Steering

  • Steering Mechanism
  • Steering Adjustment

Brakes

  • Front Brakes
  • Rear Brakes
  • Brake Lines
  • Brake Pads and Discs

Body and Frame

  • Frame Inspection
  • Frame Repair
  • Body Panels

Maintenance

  • Scheduled Maintenance
  • Lubricants and Fluids
  • Torque Specifications
  • Periodic Checks and Adjustments

Troubleshooting

  • Engine Troubleshooting
  • Electrical Troubleshooting
  • Fuel System Troubleshooting
  • Transmission Troubleshooting
  • Drivetrain Troubleshooting
  • Suspension Troubleshooting
  • Brake Troubleshooting

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Polaris 1996-2003 Polaris Sportsman 400, 500, Xplorer 500 manual Customer Reviews and Feedback

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Sara W.says...
Everything I needed to know for maintenance and repairs was right here. The email with the download link arrived promptly, making it easy to access. Thanks!
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Tom H.says...
Had a few questions about the manual, and the support team responded within hours. The download process was smooth too!
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Jake R.says...
This manual is incredibly detailed and helped me troubleshoot my Sportsman 500. The download was seamless, and I received a confirmation email almost instantly! Highly recommend!