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

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

Includes the following models

  • 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

File specifications

File size: 50.76 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 1.04 Minutes
$18.99 Instant Download

Product 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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Manuals frequently bought together

1996-2013 Polaris™ Sportsman 400, 450, 500 , Worker 500, Xplorer 500, EFI manual

- Polaris Inc Sportsman 400 (2001-2005) - Sportsman 400 HO (2011-2013) - Sportsman 450 (2006-2007) - Sportsman 450 Browning Edition (2006) - Sportsman 500 (1996-2010) - Sportsman 500 RSE (2000-2002) - Sportsman 500 DUSE (2001-2002) - Sportsman 500 HO (2001-2006, 2008-2013) - Sportsman 500 X2 (2006-2010) - Sportsman Touring 500 (2008-2013) - Worker 500 (1997-2001) - Xplorer 500 (1997) Production/model years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013.

2012-2013 Polaris™ Sportsman 400, 500 ATV manual

- 2012 Polaris Sportsman 400 HO - 2012 Polaris Sportsman 500 HO - 2013 Polaris Sportsman 400 HO - 2013 Polaris Sportsman 500 HO Production/model years: 2012, 2013

2004 Polaris Sportsman 400, Sportsman 500 ATV manual

**Sportsman 400, Sportsman 500 / Polaris Industries Inc** - **Sportsman 400** - Standard model with 425cc engine. - Available in different color options. - **Sportsman 500 H.O.** (High Output) - Enhanced 499cc high-output engine. - Features improved suspension and handling. - **Sportsman 500 DUSE** (Ducks Unlimited Special Edition) - Special edition with unique camouflage graphics. - Includes additional accessories like gun scabbards. - **Sportsman 500 RSE** (Remington Special Edition) - Remington Edition with exclusive green color and Remington branding. - Comes with upgraded wheels and additional features. - Production/model years: 2004

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