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1996-2003 Polaris Xplorer 500 Service Manual

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1996-2003 Polaris Xplorer 500 Service Manual




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    • By Jeff Cotter
      I recently purchased a 2000 polaris xplorer 400 4x4.  When I bought it the starter was bad, speedometer didn't work,  and it had been sitting for 5 years. I replaced the battery, and starter. Changed all fluids, and got it running correctly.  Then replaced the speedometer in an attempt to make sure the awd would be available when needed.  And took it out for a couple hour ride with a buddy.  
      It ran great that ride with no serious problems just a little carb issues which I was able to take care of on the trails.  Then a couple days later I decided to take it out for a ride by myself,  again ran great no issues other than a couple times it seemed to cough and then take off again.  That day when I was loading it I noticed coolant dripping onto the trailer and the overflow bottle was empty.  
      Got home and decided to drain the counter balancer, when I did that I got about 3 cups of coolant. Im guessing that it needs new seals and all for the water pump.
      My question is how difficult is it to do the water pump and should I attempt it or should I send it down the road to the polaris dealership to get it done? 
       
    • By Micah Gafford
      I've had a seriously annoying time trying to deal with the brakes on my rebuild. What size is the fitting that screws into the inverted flair cross and into the caliper? I plan on trying to make parts I need with braided steel hose.
    • By Kyle Meadows
      I am 17 and I don't have lots of money but I know my way around older 2 stroke dirtbikes but my grandpa gave me this four-wheeler and I have had nothing but issues with it. I went through gas tank/lines and the oil injection has been bypassed, I have mixed gas in the tank and it is for sure getting to the carb. I have cleaned the carb to the best of my ability. I can get it to try and start for a few seconds but won't run any longer than 5 seconds with or without ether. Please help
    • By Micah Gafford
      I'm Micah I live in southern Indiana in the Hoosier national forest. Just picked up my first ATV for extra cheap and I've gotta get it up and running from sitting in a friend's shed for a few years. It's a '95 Polaris Xplorer 400. I've had a little bit of experience with simple ATV stuff from the cheap chinese atv my in-laws bought for our kids. I don't expect nearly as many headaches but would love suggestions on what things to go through before putting in a battery, gas, and oil and trying to fire it up.
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    • By Brittany Jones
      Yes I just got a 1998 polaris xplorer 400 4x4. Ran fine after hauling then died. Cleaned carb and put new fuel filter, hose, and new battery in. Starts 3 out of 10 times but will only run for a short time. Any suggestions?



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