The Polaris Sportsman 400 and 500 All-Terrain Vehicles (ATVs), produced for the 2001 and 2002 model years, represent a significant offering in the mid-size utility ATV segment. Known for their rider-friendly features, comfortable ride, and robust utility capabilities, these ATVs are designed for a variety of uses, from recreational riding to demanding tasks for hunters, farmers, and general utility users. The Sportsman line is recognized for balancing performance with comfort and value, making it a popular choice. These vehicles typically feature liquid-cooled engines, an On-Demand All-Wheel Drive system, and independent front suspension for enhanced control and stability, embodying a heritage as a pioneer in off-road vehicles. This comprehensive workshop service and repair manual provides essential information for the maintenance, troubleshooting, and repair of the Polaris Sportsman 400 and 500 ATVs. It covers a wide range of systems, including engine, drivetrain, electrical, suspension, steering, and braking systems, offering detailed procedures from basic maintenance like oil changes and filter replacements to complete engine and transmission overhauls. The manual includes diagnostic charts, technical specifications, wiring diagrams, and schematics, equipping owners and technicians with the knowledge to ensure the optimal performance and longevity of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Vehicle Type: All-Terrain Vehicle (ATV) Model Years Covered: 2001, 2002 Product Name: Polaris Sportsman 400 500 ATV Complete Workshop Service Repair Manual 2001 2002 PDF Download Codes Vin Prefix: 4X4P 👋 Introduction Market Position Segment: Mid-size utility ATV segment. Target Audience: Recreational riders, hunters, farmers, utility users seeking reliable and capable off-road transportation. Competitive Analysis Key Competitors: Can-Am Outlander, Honda Foreman, Yamaha Kodiak, Suzuki King Quad. Positioning: Polaris Sportsman line is known for its rider-friendly features, comfortable ride, and strong utility capabilities, often balancing performance with comfort and value. Key Features Utility Focus: Designed for work and play, with robust suspension and towing capacity. User Friendliness: Generally considered easy to operate and maintain, making it a popular choice for a wide range of riders. Manual Value Purpose: Essential for owners and technicians to maintain, repair, and optimize the performance and longevity of the Polaris Sportsman 400/500. 📋 Manual Details Coverage Areas Primary Coverage: Complete workshop service and repair Additional Coverage: Maintenance, troubleshooting, diagnostics, technical specifications, diagrams, schematics Page Count Estimated Pages: Extensive (typical workshop manuals exceed 300 pages) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel system, ignition system, exhaust system Drivetrain Systems: Transmission, drive shafts, differentials, clutch, final drive Electrical Systems: Wiring diagrams, charging system, starting system, lighting, ignition, instrumentation, switches, sensors Suspension Steering: Front suspension, rear suspension, steering components, wheel alignment Braking Systems: Brake system components, hydraulic lines, calipers, rotors, parking brake Fuel System: Fuel tank, fuel pump, fuel filter, carburetor (if applicable), fuel injection system (if applicable) Body Chassis: Frame, body panels, fenders, racks, seat assembly Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, fluid checks, lubrication points Repair Procedures: Engine rebuilding, transmission overhauling, brake caliper replacement, suspension component repair, electrical diagnostics and repair Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common problem identification Technical Data: Torque specifications, clearances, tolerances, part numbers, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, allowing for quick keyword lookup of procedures and parts. Print Quality Resolution: High-resolution scans of original factory manuals, ensuring clarity of text and diagrams. Scalability: PDF format allows for zooming to view intricate details in diagrams and schematics. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single-cylinder Engine Displacement 400: 375cc Engine Type 500: 4-stroke, SOHC, 2-valve, single-cylinder Engine Displacement 500: 499cc Bore X Stroke 400: Approx. 83mm x 69mm (specifics in manual) Bore X Stroke 500: Approx. 93mm x 73.5mm (specifics in manual) Cooling System: Liquid-cooled Performance Horsepower 400: Approx. 26-28 hp (varies by source) Horsepower 500: Approx. 34-36 hp (varies by source) Torque 500: Approx. 28-30 lb-ft (varies by source) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni BSR42 for 500 model) Fuel Type: Unleaded gasoline, minimum 87 octane Ignition Ignition System: CDI (Capacitor Discharge Ignition) Lubrication Oil Type Engine: SAE 0W-40 or 10W-40 Synthetic ATV/Motorcycle Oil (refer to manual for exact specification) Oil Capacity Engine: Approx. 1.7 US quarts (1.6 liters) (refer to manual for exact capacity) 🔧 Transmission Standard Transmission Type: Automatic (Polaris PVT™ - Continuously Variable Transmission) Drive System: Shaft drive, On-Demand All-Wheel Drive (AWD) Gear Selection: High, Low, Neutral, Reverse, Park Features Clutch Type: Centrifugal clutch Belt Type: Drive belt, secondary driven pulley (PVT) Maintenance Fluid Type Transmission:...