This Clymer Polaris Sportsman/Xplorer ATV 1996-2008 Repair Manual provides service, repair and maintenance information for 2001-2005 Polaris Sportsman 400, 2006-2007 Polaris Sportsman 450, 2006 Polaris Sportsman 450 Browning Edition, 1996-2008 Polaris Sportsman 500, 2000-2002 Polaris Sportsman 500 RSE, 2001-2002 Polaris Sportsman 500 DUSE, 2001-2006 Polaris Sportsman 500 HO, 2008 Polaris Sportsman 500 HO, 2006-2008 Polaris Sportsman 500 X2, 2008 Polaris Sportsman Touring, 1997-2001 Polaris Worker 500, and 1997 Polaris Xplorer 500 ATVs.

This manual contains the following topics:

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION
Manual organization/Warnings, cautions and notes/Safety/Serial numbers/Model identification (2004 models)/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

CHAPTER TWO/TROUBLESHOOTING
Water damage/Starting the engine/Engine does not start/Poor engine performance/Electronic throttle control (ETC)/Fuel system/Engine/Engine lubrication/Cylinder leakdown test/Clutch system/Gearshift linkage/Transmission/Electrical testing/Electrical troubleshooting/Meter assembly/Front gearcase/Final drive/Front suspension and steering/Brake system/Specifications

CHAPTER THREE/ LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil/Oil pump priming/Oil pressure test/Transmission/Front gearcase oil/Front hub (1996-early 2004 models)/Clutch/Air filter/Fuel tank vent hose/Fuel hose and filter/Brake system/Control cables/Cooling system /Exhaust system/Suspension/Tires and wheels/Lubrication service/Fastener inspection/Valve clearance/Compression test/Spark plug/Ignition timing/Idle speed/Specifications

CHAPTER FOUR/ ENGINE TOP END
Engine service/Engine cooling/Engine lubrication/Servicing the engine in the frame/Exhaust system/Cylinder head cover/Rocker arm assembly/Camshaft/Cylinder head/Valves and valve components/Cylinder block/Piston and piston rings/Camshaft chain and sprockets/Break-in procedure/Specifications

CHAPTER FIVE/ENGINE LOWER END
Engine/Flywheel and stator plate/Recoil starter/Crankcase/Oil pump/Oil system one-way check valve/Break-in procedure/Specifications

CHAPTER SIX/CARBURETOR AND FUEL SYSTEM
Carburetor operation/Carburetor/Carburetor tests and adjustments/Throttle cable replacement/Starting enrichment (choke) cable/Fuel tank/Fuel shutoff valve/Fuel level sending unit (2004-on models)/Air filter air box/Fuel pump/Specifications

CHAPTER SEVEN/FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure/Depressurizing the fuel system/Fuel line fittings/Throttle body/Fuel rail and fuel injector/Fuel pump/Fuel sender/Pressure regulator/Fuel tank/Crankshaft position sensor (CPS)/Manifold air pressure (MAP) sensor/Intake air temperature (IAT) sensor/Idle air control (IAC)/Throttle position sensor (TPS)/Engine coolant temperature (ECT) sensor/Electronic control module (ECM)/Self diagnosis/Throttle cable replacement/Air filter air box/Specifications

CHAPTER EIGHT/COOLING SYSTEM
Air cooling system/Liquid cooling system/Hoses and hose clamps/Radiator/Cooling fan/Coolant pump/Thermostat/Specifications

CHAPTER NINE/CLUTCH AND DRIVE BELT
Clutch system operation/Clutch tools/Clutch drying/Drive belt/Belt alignment/Drive clutch/Driven clutch/Specifications

CHAPTER TEN/TRANSMISSION (1996-EARLY 2004 MODELS)
Transmission/Transmission inspection/Shift shafts/Front output shaft/Transmission gearcase oil seal inspection and replacement/Shift selector linkage/Specifications

CHAPTER ELEVEN/TRANSMISSION (LATE 2004-ON MODELS)
Transmission/Transmission shafts/Differential gear assembly (X2 and Touring models)/Snorkel shaft/Shift selector linkage/Specifications

CHAPTER TWELVE/FRONT DRIVE SYSTEM
Front hub and Hilliard clutch (1996-early 2004 models)/Front hub (late 2004-on, X2 and Touring models)/Front drive axle, boots and constant velocity (CV) joints/Front drive shaft/Front gearcase/Front gearcase-Deluxe models with active decent control (2007-on Sportsman 500, X2 and Touring models)/Specifications

CHAPTER THIRTEEN/ELECTRICAL SYSTEM
Electrical basics/Electrical component replacement/Electrical connectors/Battery/Battery negative terminal/Charging system/Alternator stator/Voltage regulator/rectifier (1996-early 2004 carbureted models)/Logic box (late 2004-2006 carbureted models)/Capacitor discharge ignition (carbureted models) DC/Ignition system (fuel injected models)/Ignition coil/Electric starting system/Starter drive gears/Starter solenoid/Headlight system /Taillight and work light/Indicator lamp (1996-2002 models)/Speed sensor/Transmission switch/Resistor module (2004-on models)/Shift indicator circuit (late 2004-on models)/Differential solenoid (X2 and Touring models)/Switches/Electronic throttle control (ETC) switch/All wheel drive (AWD) coil/Active descent control (ADC) coil (2007-on X2 and Touring models)/Cooling system switch and sensor/Fuses and circuit breaker (2008 models)/Speedometer/On-board diagnostics/Winch (models so equipped)/Winch contactor (models so equipped)/Specifications

CHAPTER FOURTEEN/FRONT SUSPENSION AND STEERING
Front wheel/Front strut/Front strut cartridge and spring/Control arm/Handlebar/Tie rods/Steering post/Tires and wheels/Specifications

CHAPTER FIFTEEN/REAR SUSPENSION AND FINAL DRIVE
Rear wheel/Shock absorber/Rear hub and bearing carrier /Rear drive axle/Rear drive axle boot replacement (1996-1998 models)/Rear drive axle CV joint and boots (1999-on models)/Upper control arm (all models except X2 and Touring)/Lower control arm (all models except X2 and Touring)/Upper control arm (X2 and Touring models)/Lower control arm (X2 and Touring models)/Upper and lower control arm inspection/Stabilizer linkage (all models except X2 and Touring)/Stabilizer support (all models except X2 and Touring)/Stabilizer support and bar (X2 and Touring models)/Specifications

CHAPTER SIXTEEN/BRAKES
Brake service/Front brake pad replacement/Front caliper/Output shaft brake pad replacement (1996-1997 models)/Output shaft brake caliper (1996-1997 models)/Output shaft brake pad replacement  (1998-2002 models)/Output shaft brake caliper (1998-2002 models)/Rear brake pad replacement (2003-on models except X2 and Touring)/Rear caliper (2003-on models except X2 and Touring)/Rear brake pad replacement (X2 and Touring models)/Rear caliper (X2 and Touring models)/Front master cylinder/Rear master cylinder/Brake hose replacement/Brake bleeding tips/Brake bleeding/Brake fluid draining/Rear brake pedal/Brake disc/Specifications

CHAPTER SEVENTEEN/BODY AND FRAME
Plastic inserts/Seat/Side panel/Fender cover/Front fender/Front rack, rail and grille (1996-2004 models)/Front rack and storage box (2005-on models)/Front bumper/Radiator guard (1996-2003 models)/Radiator brush guard (2004-on models)/Brush guard grill and radiator side shield  (2004-on models)/Rear rack, rail and bumper (1996-2002 models)/Rear rack and rail (2003-on except X2 and Touring)/Rear rack and handle (Touring models)/Rear fender/Rear quarter panel (X2 models)/Footwell/Footwell support bracket (X2 and Touring models)/Rear storage box (all models except X2 and Touring)/Cargo box (X2 models)/Specifications

INDEX

WIRING DIAGRAMS