This service manual provides comprehensive guidance for the Polaris Sportsman and Xplorer models manufactured between 1996 and 2003. These versatile ATVs, including various 400cc and 500cc configurations such as the Sportsman 500, Xplorer 500, and specialized editions like the Sportsman 500 RSE and Sportsman 400 Desert, are engineered for robust off-road performance. Known for their powerful twin-cylinder engines, automatic CVT transmissions with on-demand all-wheel drive, and comfortable rider ergonomics, these Polaris models have established a strong reputation for capability and reliability in recreational and utility applications.
The purpose of this manual is to serve as an essential resource for owners, amateur mechanics, and professional technicians. It covers a wide array of critical areas, including detailed maintenance procedures, routine tune-ups, lubrication schedules, and fluid specifications for the engine, drivetrain, and braking systems. Furthermore, the manual offers systematic troubleshooting guides, repair and rebuild instructions for all major components, and essential wiring diagrams to aid in electrical diagnostics. By following the information contained within, users can effectively maintain their vehicles, prevent premature wear, and ensure optimal performance and longevity.
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.
Models Covered:
1996 Sportsman 500
1997 Sportsman 500
1997 Xplorer 500
1998 Sportsman 500
1998 Worker 500
1999 Sportsman 500
1999 Worker 500
1999 Sportsman 500 RSE
2000 Sportsman 500
2000 Worker 500
2000 Sportsman 500 RSE
Sportsman 500 Remington Special Edition (Cam ouflage color scheme).
2001 Sportsman 400
2001 Sportsman 500 DUSE
2001 Sportsman 500 H.O.
2001 Sportsman 500 HO
2002 Sportsman 400
2002 Worker 400 (International)
2002 Sportsman 400 ASEI
2002 Sportsman 400 DUSE
2002 Sportsman 500 H.O .
2002 Worker 500 (International)
02 Sportsman 500 RSEl
02 Sportsman 500 DUSE1
02 Sportsman 500 H.O. Desert
02 Sportsman 500 H.O.Freedom
2003 Sportsman 400
2003 Sportsman 500 H.O.
2003 Sportsman Ducks Unlimi ted Special Edition (DUSE)
03 Sportsman Remington Special Edi tion (RSE )
2003 Sportsman 400
2003 Sportsman 400 Desert
Keep this service manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
General Information
Troubleshooting
Lubrication Maintenance And Tune-Up
Engine Top End
Engine Lower End
Fuel System
Cooling Systems
Clutch/Drive Belt System
Transmission
Front Drive System
Electrical System
Front Suspension And Steering
Rear Suspension
Brakes
Body
2001-2003 Service Information
Index
Wiring Diagrams
Maintenance
Engine
Carburetion
Clutching
Final drive
Body and steering
Transmission
Brakes
Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.
Models Covered:
1996 Sportsman 500
1997 Sportsman 500
1997 Xplorer 500
1998 Sportsman 500
1998 Worker 500
1999 Sportsman 500
1999 Worker 500
1999 Sportsman 500 RSE
2000 Sportsman 500
2000 Worker 500
2000 Sportsman 500 RSE
Sportsman 500 Remington Special Edition (Cam ouflage color scheme).
2001 Sportsman 400
2001 Sportsman 500 DUSE
2001 Sportsman 500 H.O.
2001 Sportsman 500 HO
2002 Sportsman 400
2002 Worker 400 (International)
2002 Sportsman 400 ASEI
2002 Sportsman 400 DUSE
2002 Sportsman 500 H.O .
2002 Worker 500 (International)
02 Sportsman 500 RSEl
02 Sportsman 500 DUSE1
02 Sportsman 500 H.O. Desert
02 Sportsman 500 H.O.Freedom
2003 Sportsman 400
2003 Sportsman 500 H.O.
2003 Sportsman Ducks Unlimi ted Special Edition (DUSE)
03 Sportsman Remington Special Edi tion (RSE )
2003 Sportsman 400
2003 Sportsman 400 Desert
Keep this service manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
General Information
Troubleshooting
Lubrication Maintenance And Tune-Up
Engine Top End
Engine Lower End
Fuel System
Cooling Systems
Clutch/Drive Belt System
Transmission
Front Drive System
Electrical System
Front Suspension And Steering
Rear Suspension
Brakes
Body
2001-2003 Service Information
Index
Wiring Diagrams
Maintenance
Engine
Carburetion
Clutching
Final drive
Body and steering
Transmission
Brakes
Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
