🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2002 Model Variant: 400, 500 Product Type: Service Repair Manual 👋 Introduction Market Position Segment: Utility ATV (All-Terrain Vehicle) Competitive Analysis Key Competitors 2002: Honda Foreman, Yamaha Kodiak, Suzuki QuadRunner, Kawasaki Prairie Key Features Vehicle Versatility: Designed for utility, recreation, and trail riding with robust carrying capacity. Key Features Manual Authenticity: Genuine factory service manual, ensuring accuracy and completeness. 📋 Manual Details Coverage Areas Coverage Scope: All systems, maintenance, and repairs Page Count Page Count: 355 Manual Type Manual Type: Factory Service Manual Language Language: Spanish (ESPANOL) Format File Format: PDF Delivery Delivery Method: Digital Download (ZIP) 📖 Manual Coverage Systems Covered Engine Mechanics: Complete engine disassembly, assembly, timing, lubrication, cooling, starting, and charging systems. Fuel System: Carburetor adjustment, fuel pump, fuel tank, lines, and filters. Drivetrain: Transmission (PVT - Polaris Variable Transmission), final drive, front and rear differentials, driveshafts, and CV joints. Suspension: Front and rear suspension systems, shock absorbers, control arms, ball joints, and steering linkage. Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, and rotors. Electrical System: Battery, charging system, ignition system, lighting, accessories, and starter motor. Wiring Diagrams: Comprehensive, high-quality wiring diagrams for all electrical circuits. Body And Chassis: Frame, body panels, racks, and seating. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, and lubrication points. Troubleshooting: Diagnostic procedures and common issue resolution. Repair Procedures: Step-by-step instructions for component disassembly and reassembly. Tune Up: Engine tuning, carburetor synchronization, and ignition timing adjustments. Technical Data: Specifications, tolerances, and torque values for all components. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission overhauls. 📊 Manual Specifications File Format Print Quality: High Quality, Fully Printable Navigation Bookmarking: Bookmarked for easy navigation Content Quality Illustrations: Hundreds of detailed illustrations and diagrams ⚙️ Engine Specifications Primary Engine 400 Engine Type: 4-stroke, Single Cylinder Displacement: 376cc Bore X Stroke: 80mm x 74.4mm Cooling System: Liquid-Cooled Primary Engine 500 Engine Type: 4-stroke, Single Cylinder Displacement: 499cc Bore X Stroke: 92mm x 76mm Cooling System: Liquid-Cooled Fuel System Carburetor Type: Mikuni VM32SS (400), Mikuni BSR42 (500) Ignition Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Drive System Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Drive Modes: 2WD/4WD (On-Demand All-Wheel Drive) Gear Selection: Automatic (High, Low, Neutral, Reverse, Park) Transmission Fluid Fluid Type: Polaris PS-4 4-stroke Synthetic Oil (refer to manual for specific viscosity and capacity) 📐 Dimensions Exterior Dimensions Length: Approx. 81 in (205.7 cm) Width: Approx. 46 in (116.8 cm) Height: Approx. 47 in (119.4 cm) Cargo Capacity Front Rack Capacity: Approx. 90 lbs (41 kg) Rear Rack Capacity: Approx. 180 lbs (82 kg) Weights Dry Weight: Approx. 570-590 lbs (258-268 kg) depending on model variant Wheelbase Wheelbase: Approx. 50.5 in (128.3 cm) Ground Clearance Ground Clearance: Approx. 10.25 in (26 cm) 🛡️ Safety Features Ratings Atv Safety Standards: Meets ANSI and SFI standards for ATVs. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Lighting: Dual 25W headlights, 8W taillight. 💡 Technology Features Infotainment Instrumentation: Digital odometer, speedometer, fuel gauge, 4WD indicator, high/low gear indicator, neutral indicator, reverse indicator, oil light. Driver Assistance Engine Braking: Integrated engine braking within the PVT system for downhill control. Connectivity Charging System: 12V DC electrical system with charging output for battery. 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or 6 months (refer to manual for precise recommendations). Air Filter Maintenance: Inspect every 25 hours, clean/replace as needed (more frequently in dusty conditions). Spark Plug Replacement: Refer to manual for recommended interval based on usage. Fluid Specifications Engine Oil Type: Polaris PS-4 4-stroke Synthetic Oil (or equivalent SAE 5W-50). Engine Oil Capacity: Refer to manual for specific capacity (typically around 2.1 quarts / 2.0 liters). Coolant Type: Ethylene Glycol based antifreeze (50/50 mix with distilled water). Known Issues Common Wear Items: PVT belt, wheel bearings, tie rod ends, ball joints due to demanding use. Carburetor Tuning: May require occasional adjustment or cleaning, especially if fuel quality varies. 📚 Vehicle History Brand Heritage Polaris History: Polaris Inc. is an American manufacturer of snowmobiles, ATVs, motorcycles, and UTVs, known for innovation in the powersports industry since 1954. Model Evolution Sportsman Lineage: The Sportsman line, introduced in 1993, became a benchmark for utility and comfort in the ATV market, evolving through various engine sizes and feature packages. Production Manufacturing Location: Spirit Lake, Iowa, USA 🏆 Awards & Recognition Recognitions Atv Industry Awards: Polaris Sportsman series generally received positive reviews from ATV publications for its performance and utility throughout the early 2000s.