This manual covers the All-Terrain Vehicle (ATV) models from 2001 and 2002, including the 400, 500 DUSE, and 500 H.O. variants. The is recognized for its robust engineering, offering a blend of utility and recreational capability. These ATVs are designed for a variety of terrains and tasks, from trail riding to hauling, and are known for their reliable engines, independent front suspension, and automatic transmission with all-wheel-drive engagement. The 500 H.O. models, in particular, offer enhanced performance with their high-output engines. This comprehensive workshop service repair manual provides detailed information essential for the maintenance and repair of your. It covers all major systems, including the engine, fuel, ignition, transmission, drivetrain, cooling, electrical, braking, suspension, steering, bodywork, chassis, and exhaust. Within these sections, you will find step-by-step repair instructions, diagnostic procedures, troubleshooting guides, and critical technical specifications such as torque values and fluid capacities. This manual is an invaluable resource for owners and technicians seeking to ensure the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Model Variant: 400, 500 DUSE, 500 H.O. Model Year: 2001, 2002 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Vehicle Segment: Entry-level to mid-range utility ATV. Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Wolverine, Suzuki King Quad. Key Features Powertrain: Known for reliable Polaris engines, particularly the 500cc HO variant. Suspension: Independent front suspension (IFS) and swingarm rear suspension (on most models) offering good comfort and capability. Utility: Designed for work and recreational trail riding, with rack capacity for hauling. Manual Value Proposition Diy Capability: Enables owners to perform a wide range of maintenance and repair tasks themselves, saving on labor costs. 📋 Manual Details Coverage Areas Coverage Type: Complete Workshop Service Repair Page Count Estimated Page Count: Refer to manual for exact count Manual Type Manual Format: Downloadable PDF Language Language: English Format File Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, overhaul, troubleshooting for 400cc and 500cc engine variants. Fuel System: Carburetor service, fuel pump, fuel lines, fuel tank maintenance, troubleshooting. Ignition System: Spark plug service, ignition coil testing, CDI unit diagnosis, stator and rotor inspection. Transmission Drivetrain: CVT (Continuously Variable Transmission) belt inspection and replacement, clutch service, gearbox maintenance, driveshaft and U-joint checks. Cooling System: Radiator service, fan operation, thermostat replacement, coolant flush procedures. Electrical System: Battery testing and maintenance, starter motor, charging system (alternator/stator), lighting, wiring diagrams, switch operation, fuse replacement. Braking System: Brake pad replacement, caliper service, brake fluid bleeding, master cylinder inspection, brake line maintenance. Suspension Steering: Front and rear suspension component inspection and replacement, shock absorber service, steering linkage, tie rod ends, wheel alignment procedures. Bodywork Chassis: Frame inspection, plastic panel removal and installation, seat maintenance, handlebars, fenders, racks. Exhaust System: Muffler and exhaust pipe inspection, gasket replacement, heat shield maintenance. Procedures Included Maintenance: Routine service, oil changes, filter replacements, lubrication points, general inspection checks. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for common issues. Repair: Step-by-step instructions for component replacement and repair. Rebuilds: Detailed procedures for engine and transmission overhauls. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values. Technical Depth Diagnostic Capabilities: Comprehensive diagnostic procedures for all major systems, including electrical and mechanical components. Repair Complexity: Covers basic maintenance to complete engine and transmission rebuilds. Wiring Diagrams: Includes detailed electrical system wiring diagrams for troubleshooting and component identification. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution for clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Text Search: Searchable text for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, liquid-cooled, single-cylinder. Engine Type 500: 4-stroke, liquid-cooled, SOHC, single-cylinder. Displacement 400: Approximately 375cc (specific for 400 models of this era). Displacement 500: Approximately 499cc (specific for 500 models of this era). Performance Horsepower Estimate 400: Estimated 25-30 HP range. Horsepower Estimate 500 Ho: Estimated 30-35 HP range (HO - High Output). Fuel System Carburetion 400: Mikuni or Keihin carburetor (specific size varies). Carburetion 500: Mikuni or Keihin carburetor (specific size varies, often larger for HO). Cooling System Cooling Method: Liquid-cooled with a fan assist. Lubrication Oil Type Specification: SAE 5W-50 Synthetic or 10W-40 (Refer to manual for exact Polaris recommendation). 🔧 Transmission Standard Transmission Type: Automatic with Polaris Variable Transmission (PVT) and Engine Braking. Optional Transmission Options: N/A (Standard automatic CVT). Features Drive Modes: 2WD/4WD selector with AWD (All-Wheel Drive) engagement. Gear Selection: High, Low, Neutral, Reverse, Park. Fluid Type Transmission Fluid Spec: Polaris PVT Fluid (or equivalent like AGL Synthetic Gearcase Lubricant for specific components). 📐 Dimensions Exterior Length: Approx. 81 inches (2057 mm). Width: Approx. 46 inches (1168 mm). Height: Approx. 47 inches (1194 mm). Weights Dry Weight: Approx. 600-650 lbs (272-295 kg). Ground Clearance: Approx. 10.5 inches (267 mm). Cargo Rack...