Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Codes Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Introduction Market Position Positioning: The Polaris Sportsman series established itself as a benchmark for utility and recreational ATVs during the late 1990s and early 2000s. This manual caters to owners of these capable machines. Competitive Analysis Competitors: Competed with models from Honda (FourTrax), Yamaha (Grizzly), Kawasaki (Bayou/Brute Force), and Suzuki (KingQuad) in the mid-size utility ATV segment. Key Features Vehicle Features: Independent Rear Suspension (IRS) was a significant differentiator for many Sportsman models, offering a smoother ride and better handling compared to solid axle designs of some competitors. Manual Details Coverage Areas Primary Coverage: Complete factory service and repair procedures Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, diagnosis, tuning, cylinder head, piston, crankshaft, valve train, timing Fuel System: Carburetor service and adjustment, fuel pump, fuel lines, fuel tank, filtration Ignition System: Ignition coil, spark plug service, CDI unit, timing adjustments Cooling System: Radiator, fan, coolant hoses, thermostat, water pump service and replacement Drivetrain Transmission: Automatic transmission service, belt drive system, clutch, gearbox overhaul, drive shafts, differentials Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications Steering System: Handlebar assembly, tie rods, steering column, steering rack/gearbox service and adjustment Braking System: Front and rear brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications, bleeding procedures Electrical System: Wiring diagrams, battery service, charging system (stator, regulator/rectifier), starter motor, lighting, ignition switch, switches, fuses Body And Frame: Body panel removal and installation, seat, handlebars, fenders, frame inspection, chassis components Troubleshooting: Extensive diagnostic charts and procedures for common and uncommon issues Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, brake inspections, chain/belt adjustments, lubrication Major Repairs: Engine rebuilds, transmission overhaul, suspension replacement, electrical component repair Diagnostics: Step-by-step troubleshooting guides for all major systems Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Wiring Diagrams: Detailed electrical schematics for all model years and configurations Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable Print Quality Printability: Printable on standard office printers Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC (Single Overhead Cam) Displacement 400: 375cc (approx.) Displacement 500: 499cc (approx.) Performance Horsepower 500: Approx. 30-35 HP (varies by specific model year and tune) Torque 500: Approx. 30-35 ft-lbs (varies by specific model year and tune) Fuel System Carburetor Type: Mikuni (specific model varies, e.g., VM34/VM36 carburetors are common) Fuel Type: Unleaded gasoline, minimum 87 octane Ignition System Spark Plug Type: NGK DPR7EA-9 (or equivalent, check manual for exact fitment) Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Optional Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: Shaft drive (typically AWD/4WD engageable via electronic switch, 2WD mode also available) Transmission Fluid Type: Polaris AGL Premium Synthetic Gearcase Oil (or equivalent meeting specifications) Transmission Fluid Capacity: Refer to manual for specific capacities (typically ~1-2 quarts for gearcase) Dimensions Exterior Wheelbase: Approx. 50.2 inches (127.5 cm) Length: Approx. 83 inches (210.8 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 49.5 inches (125.7 cm) Cargo Front Rack Capacity: Approx. 100 lbs (45 kg) Rear Rack Capacity: Approx. 200 lbs (90 kg) Weights Dry Weight: Approx. 600-650 lbs (272-295 kg) (varies by model year/features) Towing Capacity: Approx. 1,050 lbs (476 kg) Wheels Tires Front Tire Size: 25x8-12 or 26x8-12 (common) Rear Tire Size: 25x11-12 or 26x11-12 (common) Wheel Bolt Pattern: 4x110mm (check specific model for confirmation) Safety Features Ratings Atv Safety: ATV safety is highly dependent on operator skill, adherence to trail recommendations, and proper maintenance. This manual provides essential information for safe operation. Active Features Braking System Design: Hydraulic disc brakes on all wheels for effective stopping power. Passive Features Rollover Protection: No integrated ROPS. Operator must wear helmet and protective gear. Technology Features Infotainment Infotainment Features: Basic functionality: standard headlights, taillights, brake lights. No advanced infotainment systems typical of modern vehicles. Driver Assistance Assistance Features: Key feature is the Polaris AWD system which automatically engages front wheels when rear wheels slip. Electronic activation of 4WD is also a common feature. Connectivity Connectivity Options: None. Basic electrical systems for operation. Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months (whichever comes first), check manual for specific recommendations. Air Filter Cleaning: Check every 20 hours, clean as needed. Replace when damaged. Spark Plug Replacement: Every 100 hours or 12 months. Check gap before installation. Transmission Fluid Change: Every 200 hours or 24 months. Inspect regularly. Fluid Specifications...