This comprehensive service repair manual provides detailed instructions and high-quality diagrams for servicing and repairing your 1996-2003 Polaris Sportsman 400 and 500, including the Xplorer 500 models. This manual covers a wide range of topics, from basic maintenance and tune-ups to complex engine and transmission repairs. You'll find detailed information on troubleshooting, engine top and bottom end, fuel systems, cooling systems, clutch and drive belt systems, transmissions, front and rear suspension, brakes, electrical systems, and much more. This manual is a valuable resource for do-it-yourself mechanics, providing clear and concise instructions to help you keep your ATV running smoothly. The manual covers the following models: * 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 * 2000 Sportsman 500 Remington Special Edition (Camouflage 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) * 2002 Sportsman 500 RSEl * 2002 Sportsman 500 DUSE1 * 2002 Sportsman 500 H.O. Desert * 2002 Sportsman 500 H.O. Freedom * 2003 Sportsman 400 * 2003 Sportsman 500 H.O. * 2003 Sportsman Ducks Unlimited Special Edition (DUSE) * 2003 Sportsman Remington Special Edition (RSE) * 2003 Sportsman 400 * 2003 Sportsman 400 Desert The manual includes detailed sections on: * 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

The 1996-2003 Polaris Sportsman 400 and 500, along with the Xplorer 500, represent a pivotal era in the history of Polaris ATVs. These models were designed for both recreational use and light-duty work, offering a balance of power, versatility, and durability that made them popular choices for riders of various skill levels. The Sportsman 400 and 500 featured liquid-cooled, single-cylinder engines, providing ample power for traversing varied terrain, while the Xplorer 500 boasted a more rugged and utilitarian design, emphasizing its capability for hauling and towing. Notably, the Sportsman 500 line saw the introduction of the "H.O." (High Output) engine in 2001, adding even more power to the mix. Several special edition models were also released during this period, including the Sportsman 500 Remington Special Edition, which featured a camouflage paint scheme, and the Sportsman 500 Ducks Unlimited Special Edition, catered towards hunters and enthusiasts. The popularity of these Polaris models was further fueled by their robust construction and user-friendly features. They included a proven independent front suspension system for a smooth ride over rough terrain, a reliable shaft-driven rear end for low-maintenance operation, and a convenient electric start system. Over the years, these models received numerous updates, including improvements in engine performance, braking systems, and suspension components, further solidifying their reputation as dependable and capable off-road vehicles. This comprehensive service repair manual for the 1996-2003 Polaris Sportsman 400, 500, and Xplorer 500 serves as a vital resource for owners and mechanics alike, providing detailed information on maintenance, troubleshooting, and repair procedures, empowering individuals to keep these iconic ATVs running smoothly for years to come.