This manual covers the 2002 Sportsman 400, a versatile all-terrain vehicle renowned for its robust engineering and off-road capability. Designed for a wide range of uses from utility tasks to recreational trail riding, the Sportsman 400 offers a balanced blend of power and handling. Its liquid-cooled, approximately 375cc to 400cc engine, coupled with a Continuously Variable Transmission (CVT) and on-demand All-Wheel Drive (AWD) system, ensures reliable performance in various terrains. The vehicle's design prioritizes durability and ease of operation, making it a trusted companion for demanding outdoor activities. This factory service repair manual provides comprehensive guidance for the maintenance, troubleshooting, and repair of your 2002 Sportsman 400. It details procedures for all major systems, including the engine, fuel system, cooling, exhaust, transmission, drivetrain, suspension, steering, brakes, and electrical systems. The manual includes step-by-step instructions for component removal and installation, detailed diagnostic procedures, and essential technical specifications. Its thorough coverage empowers owners and technicians to effectively maintain the vehicle, ensuring optimal performance, longevity, and safe operation. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2002 Codes Engine Code: Likely 276cc or similar, specific code not provided in product info but typical for 400cc class ATVs of the era. Chassis Code: Specific chassis code not provided in product info, but refers to the Polaris Sportsman platform. 👋 Introduction Market Position Target Audience: Owners of 2002 Polaris Sportsman 400 seeking to perform maintenance, repairs, or diagnostics. Competitive Analysis Value Proposition: Provides factory-level technical data and procedures, enabling cost-effective DIY repairs and maintenance, ensuring optimal vehicle performance and longevity. Key Features Ease Of Use: Described as a handy, easy-to-read reference book with sequentially ordered steps. Comprehensiveness: Covers all installation, removal, disassembly, assembly, repair, and check procedures. 📋 Manual Details Coverage Areas Systems Covered: Engine, transmission, drivetrain, chassis, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, bodywork, and troubleshooting. Page Count Page Count: Actual page count not specified in product information. Typical factory service manuals for this era range from 300-600 pages. Manual Type Manual Type: Factory Service Repair Manual Language Language: English (assumed for North American market, typical for Polaris manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, repair, and reassembly of all internal engine components including cylinder head, pistons, crankshaft, camshaft, valves, timing components, and lubrication system. Engine Fuel System: Carburetor (model specific, likely Mikuni) adjustment, cleaning, and rebuilding; fuel pump operation and testing; fuel tank and lines. Cooling System: Radiator, fan, water pump, thermostat, and coolant flow diagnostics and maintenance. Exhaust System: Muffler, exhaust pipes, and heat shields; inspection for leaks and damage. Transmission Drivetrain: CVT (Continuously Variable Transmission) operation, belt inspection and replacement, clutch assembly servicing, gearbox maintenance, and driveshaft/axle inspection. Suspension Steering: Front and rear suspension component inspection, ball joint and tie rod end servicing, steering linkage alignment, and shock absorber replacement. Braking System: Hydraulic brake system diagnostics, brake pad and rotor replacement, brake caliper servicing, and brake fluid bleeding procedures. Electrical System: Battery maintenance, charging system (stator, regulator/rectifier) testing, starter motor and solenoid testing, lighting system troubleshooting, and ignition system diagnostics. Bodywork Chassis: Frame inspection, plastic body panel removal and installation, seat servicing, and rack inspection. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, battery testing and charging, tire pressure checks, and general lubrication. Repair Procedures: Complete engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnostics and replacement, and bodywork repairs. Troubleshooting Guides: Systematic diagnostic flowcharts for common starting, running, electrical, and mechanical problems. Installation Removal: Step-by-step instructions for removing and installing major components and sub-assemblies. Technical Depth Depth Of Coverage: Comprehensive, covering basic maintenance to full engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics. Diagnostic Capabilities: Detailed diagnostic procedures and specifications for electrical components, fuel system, and engine performance. Rebuild Instructions: Includes detailed procedures for complete engine and transmission rebuilding, with torque specifications and clearances. 📊 Manual Specifications File Format File Format: PDF Searchability: Typically searchable text within the PDF, allowing for quick access to information. Print Quality: PDF format allows for high-quality printing of all diagrams, illustrations, and text. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: Likely a 4-stroke, single-cylinder gasoline engine. Displacement: Approximately 375cc to 400cc. Specific Polaris designation might be 375 or 400. Bore X Stroke: Specifics not in product info but typical for this class, e.g., 83mm x 71.3mm or similar. Cooling System: Liquid-cooled (typical for Polaris Sportsman 400 of this era). Ignition System: CDI (Capacitor Discharge Ignition) with electronic timing. Performance Horsepower: Estimated 25-30 HP. Specific figures require referring to the manual's detailed specifications. Torque: Estimated 20-25 ft-lbs. Specific figures require referring to the manual's detailed specifications. Fuel System Fuel Delivery:...