🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2002 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Segment: Mid-size utility ATV segment, known for versatility and recreational capability. Competitive Analysis Competitors: Competed with models from Honda (FourTrax), Yamaha (Grizzly), Suzuki (KingQuad), and Kawasaki (Bayou). Key Features Features: Independent front suspension, selectable 2WD/4WD, powerful engines for their class, and Polaris's signature automatic transmission (PVT). Target Audience Audience: Recreational riders, hunters, farmers, and utility users seeking a capable and reliable ATV. 📋 Manual Details Coverage Areas Covered Models: Polaris Sportsman 400, Polaris Sportsman 500 Coverage Scope: Complete tear down and rebuild, maintenance, troubleshooting, repair. Page Count Estimated Pages: Likely 300-500 pages based on typical factory service manuals for this era and vehicle type. Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed specifications, disassembly, assembly, troubleshooting, tuning for both 400cc and 500cc variants. Transmission: CVT system (Primary and Secondary Clutch), gear case, drive system diagnostics and repair. Drivetrain: 4WD system, front differential, rear differential, drive shafts, U-joints. Suspension: Front and rear suspension components, shock absorbers, A-arms, bearings, alignment. Brakes: Hydraulic brake system, caliper service, master cylinder, brake lines, bleeding procedures. Electrical System: Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), starter motor, battery, lighting. Fuel System: Carburetor(s) service and tuning, fuel pump, fuel lines, fuel tank. Cooling System: Radiator, fan, coolant, thermostat, water pump. Frame And Body: Chassis components, body panels, seat, handlebars, fenders. Steering: Steering mechanism, tie rods, ball joints, steering wheel. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, lubrication, brake adjustments. Troubleshooting: Systematic diagnostic procedures for common problems, fault finding charts. Repair: Step-by-step instructions for component repair and replacement. Rebuild: Complete engine and transmission rebuild procedures. Diagnostics: Electrical diagnostics, component testing, performance checks. Assembly: Detailed procedures for reassembling components after repair or overhaul. Technical Depth Depth: Comprehensive, suitable for both DIY enthusiasts and professional technicians. Covers from basic maintenance to complete engine rebuilds. Visuals: Includes pictures and part diagrams to illustrate procedures and component identification. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within PDFs, allowing for quick information retrieval. Print Quality Quality: Digital format allows for high-quality printing of specific pages or the entire manual. Binding Type Type: N/A (Digital PDF Download) Paper Type Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Model 400 Engine Type: 4-stroke, SOHC, 2-valve, single-cylinder Model 400 Displacement: 375cc (approx.) Model 500 Engine Type: 4-stroke, SOHC, 2-valve, single-cylinder Model 500 Displacement: 499cc (approx.) Performance Model 400 Horsepower: Approx. 24-26 HP (subject to variation) Model 500 Horsepower: Approx. 30-32 HP (subject to variation) Fuel System Fuel Delivery: Carbureted (e.g., Mikuni BSR series common for this era) Fuel Type: Unleaded Gasoline (91+ octane recommended) Ignition System: CDI (Capacitor Discharge Ignition) Cooling System: Liquid-cooled 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with engine braking Gear Selection: High, Low, Neutral, Reverse, Park Features Clutch Type: Automatic, belt-driven, centrifugal clutch system (primary and secondary) Drive Modes: 2WD/4WD On-Demand Fluid Type Specification: Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 GL-5 gear oil for differential/transaxle components if separate) 📐 Dimensions Exterior Wheelbase: Approx. 50.5 inches (128.3 cm) Length: Approx. 83 inches (210.8 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 47 inches (119.4 cm) Weights Dry Weight: Approx. 570-600 lbs (258-272 kg) depending on model variant Towing Capacity: Typically rated at 1500 lbs (680 kg) Rack Capacity Front: Typically rated at 90 lbs (41 kg) Rack Capacity Rear: Typically rated at 200 lbs (90 kg) 🛡️ Safety Features Ratings Safety Standards: Manufactured to meet relevant ATV safety standards of the time; operator must wear appropriate safety gear. Active Features Braking System: Hydraulic disc brakes, front and rear. Engine Braking: Integrated into the PVT system for downhill control. Passive Features Frame Construction: Steel frame designed for stability and durability. Ergonomics: Designed for rider control and comfort. 💡 Technology Features Infotainment Features: Basic dashboard indicators (speedometer, odometer, fuel gauge, 4WD indicator, engine warning light). Driver Assistance Features: On-demand 4WD system, engine braking. Connectivity Features: N/A (No advanced connectivity features typical for modern vehicles). 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months, whichever comes first. Air Filter Cleaning: Inspect every 50 hours, clean or replace as needed. More frequently in dusty conditions. Spark Plug Replacement: Check and gap every 50 hours; replace as needed (refer to manual for specific plug type and gap). Transmission Oil Change: Refer to manual, typically every 200 hours or 24 months for gearcase lubricant. CVT belt inspection at 50-100 hour intervals. Fluid Specifications Engine Oil: Polaris PS-4 10W-40 Synthetic or AMSOIL 4-Stroke Synthetic Motor Oil SAE 10W-40 (specific recommendations may vary, consult manual). Coolant: Ethylene glycol-based antifreeze (50/50 mix with distilled...