This manual covers the Sportsman Xplorer 400 4WD and 500 4WD models produced between 2000 and 2003. Known for their robust 4WD systems, independent suspension, and comfortable ergonomics, these ATVs are engineered for demanding off-road use and utility tasks. The brand has a strong heritage in powersports, with the Sportsman line consistently recognized for durability and performance, making the Xplorer a capable choice for recreational riders and those requiring reliable off-road capability.
This comprehensive workshop service repair manual provides factory-level information essential for maintaining and repairing your Sportsman Xplorer. It details all aspects of the vehicle, including engine, transmission, drivetrain, suspension, brakes, and electrical systems. With step-by-step procedures for routine maintenance, troubleshooting, and complex repairs, this manual is an invaluable resource for professional technicians and experienced owners alike, ensuring optimal performance and longevity of your ATV.
This is the factory/official manual used for repair and maintenance such as tune-ups, lubrication and major engine or transmission rebuild your vehicle might require
Accurate and detailed technical yet friendly and easy to follow instructions, charts and diagrams for the professional or anyone with basic mechanical knowledge to safely and easily service their vehicle.
OEM specifications such as torque, fuel pressure chart, electrical and connectors data, compression ranges, minimum and maximum tolerances, parts numbers or paint codes among other.
STEP BY STEP REPAIRS
All of the procedures in this manual are organized in a sequential, step-by-step format.
The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly and inspections.
EXPLODED DIAGRAM, CHARTS ILLUSTRATIONS AND PHOTOS
Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and re-assembly procedures.
This is the factory/official manual used for repair and maintenance such as tune-ups, lubrication and major engine or transmission rebuild your vehicle might require
Accurate and detailed technical yet friendly and easy to follow instructions, charts and diagrams for the professional or anyone with basic mechanical knowledge to safely and easily service their vehicle.
OEM specifications such as torque, fuel pressure chart, electrical and connectors data, compression ranges, minimum and maximum tolerances, parts numbers or paint codes among other.
STEP BY STEP REPAIRS
All of the procedures in this manual are organized in a sequential, step-by-step format.
The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly and inspections.
EXPLODED DIAGRAM, CHARTS ILLUSTRATIONS AND PHOTOS
Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and re-assembly procedures.
