This manual covers the 400 and 500 models from the 2001 and 2002 model years. These all-terrain vehicles are engineered for rugged utility and reliable performance across varied terrain, offering robust capabilities for recreational riders and utility users alike. Known for their strong four-wheel-drive systems and comfortable ride, the series has been a significant offering in the powersports market, building on a heritage in powersports vehicle manufacturing. This comprehensive service repair manual provides essential information for the maintenance and repair of your vehicle. It details procedures for engine overhaul, transmission service, drivetrain maintenance, suspension and steering adjustments, brake system repair, and electrical diagnostics. The manual also includes routine maintenance schedules, troubleshooting guides, component replacement instructions, and technical specifications, making it an indispensable resource for owners and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Model Variant: 400, 500 Model Years Covered: 2001, 2002 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) Target User: Recreational riders, utility users, and DIY mechanics. Competitive Analysis Key Competitors Era: Honda FourTrax, Yamaha Kodiak, Suzuki King Quad. Key Features Vehicle Focus: Rugged utility, reliable performance for varied terrain. Manual Value: Essential for maintaining optimal performance and longevity of the vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Polaris Sportsman 400 and 500 models. Specific Systems: Engine, transmission, drivetrain, suspension, brakes, electrical system, fuel system, cooling system, bodywork, chassis. Page Count Estimated Page Count: Over 300 pages (typical for comprehensive service manuals of this era). Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Overhaul: Detailed procedures for engine disassembly, inspection, repair, and reassembly. Transmission Service: Information on transmission operation, troubleshooting, and repair for automatic/CVT systems. Drivetrain Maintenance: Coverage of front and rear differentials, driveshafts, and U-joints. Suspension And Steering: Procedures for inspecting, repairing, and adjusting front and rear suspension components and steering systems. Brake System Repair: Details on hydraulic brake systems, including caliper, master cylinder, and bleeding procedures. Electrical Diagnostics: Wiring diagrams, troubleshooting guides for ignition, charging, lighting, and accessories. Fuel System Troubleshooting: Carburetor service, fuel pump operation, and fuel line maintenance. Cooling System Service: Radiator, fan, thermostat, and coolant maintenance procedures. Bodywork And Chassis: Information on body panel removal, frame inspection, and component mounting. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, and general inspections. Troubleshooting Guides: Diagnostic flowcharts and symptom-based problem-solving for common issues. Component Replacement: Step-by-step instructions for replacing major and minor components. Rebuilding Procedures: Detailed instructions for rebuilding engine components, carburetors, and differentials. Torque Specifications: Precise torque values for all critical fasteners. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostics: Advanced diagnostic procedures and troubleshooting for electrical and mechanical systems. Special Tools: Identification of specific tools required for certain repair procedures. 📊 Manual Specifications File Format Format Details: Searchable PDF for easy navigation and keyword finding. Print Quality Quality: High-resolution scans of original factory manual content. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-Cooled, SOHC Displacements: 375cc (Sportsman 400), 499cc (Sportsman 500) Bore X Stroke 400: 82mm x 71.2mm (approximate, refer to manual for exact) Bore X Stroke 500: 92mm x 71.2mm (approximate, refer to manual for exact) Compression Ratio: Typically around 8.4:1 or 9.0:1 (check manual for specific variant) Performance Horsepower 400: Approx. 24-28 HP (refer to manual for exact) Horsepower 500: Approx. 30-34 HP (refer to manual for exact) Fuel System Fuel Delivery: Carbureted (Mikuni VM34SS or similar for 500, smaller for 400) Fuel Type: Unleaded Gasoline, 87 Octane (minimum) Fuel Capacity: Typically around 3.4 - 3.7 gallons (13-14 liters) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with High/Low range Optional Gearbox: Not Applicable (CVT is standard) Features Drive Modes: 2WD/4WD selector, Engine Braking Transmission Fluid Type: Polaris AGL or equivalent (refer to manual for precise spec and capacity) 📐 Dimensions Exterior Length: Approx. 81-83 inches (206-211 cm) Width: Approx. 46-48 inches (117-122 cm) Height: Approx. 48-50 inches (122-127 cm) Wheelbase: Approx. 50-52 inches (127-132 cm) Weights Dry Weight: Approx. 550-650 lbs (250-295 kg) Towing Capacity: Typically rated at 1,500 lbs (680 kg) Rack Capacity Front: Typically around 90 lbs (41 kg) Rack Capacity Rear: Typically around 180 lbs (82 kg) 🛡️ Safety Features Ratings Classification: All-Terrain Vehicle (ATV) - Off-road use only. Active Features Braking System: Hydraulic disc brakes (front and rear). Parking Brake: Mechanical parking brake, often integrated with transmission or caliper. Passive Features Lighting: Dual headlights, taillight/brake light. Operator Safety: Thumb throttle for controlled acceleration, hand brake levers. 💡 Technology Features Infotainment Features: Basic instrument cluster: speedometer, odometer, fuel gauge, warning lights. Driver Assistance Features: N/A (No electronic driver-assistance systems in this...