The Polaris Sportsman is a robust and versatile all-terrain vehicle (ATV) designed for both utility and recreational use. Introduced in 2002, this model line is celebrated for its strong engineering, reliable performance, and adaptability to various terrains and tasks. Key features include powerful single-cylinder, liquid-cooled engines, with variants offering both carbureted and electronic fuel injection (EFI) systems for enhanced efficiency and power delivery. The Sportsman is known for its substantial towing capacity, ample rack storage, and impressive ground clearance, making it a capable companion for demanding jobs and adventurous trail riding. This service repair manual provides comprehensive guidance for maintaining and repairing the 2002 Polaris Sportsman models, including the 400, 500 DUSE, 500 H.O., and 500 RSE. It covers essential areas such as general information, detailed specifications, periodic checks and adjustments, chassis maintenance, engine service, cooling system, fuel injection system, and the electrical system. The manual offers step-by-step instructions for troubleshooting, repair, diagnostics, and preventative maintenance, ensuring that owners and technicians can effectively service and restore the vehicle to optimal operating condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2002 Platform: ATV Codes Engine Variant Codes: DUSE, H.O. (High Output), RSE 👋 Introduction Market Position Vehicle Segment: Heavy-duty All-Terrain Vehicle (ATV), utility and recreational Competitive Analysis Key Competitors 2002: Yamaha Wolverine, Arctic Cat 500, Honda Foreman, Kawasaki Bayou Key Features Atv Attributes: Known for robust build, versatility for work and trail riding, independent rear suspension (IRS) on some models, strong engine performance. 📋 Manual Details Coverage Areas Specific Models Covered: Polaris Sportsman 400, Polaris Sportsman 500 DUSE, Polaris Sportsman 500 H.O., Polaris Sportsman 500 RSE Page Count Estimated Page Count: Variable (typically 300-500 pages for comprehensive ATV manuals, exact count not specified in product info) Manual Type Type: Service Repair Manual (Factory/Workshop Equivalent) Language Language: English (implied by product description and typical market for these vehicles) Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Major Systems: General Information, Specifications, Periodic Checks & Adjustments, Chassis, Engine, Cooling System, Fuel Injection System, Electrical System Procedures Included Repair And Maintenance: Troubleshooting, Repair, Service, Restoration, Rebuilding, Diagnostics, Preventative Maintenance Technical Depth Diagnostic And Rebuild Capabilities: Detailed step-by-step instructions for complex repairs, diagnostics, and rebuilds; suitable for professional technicians and DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF (requires PDF reader, may be zipped requiring WinZip/WinRAR) Print Quality Printability: Printable on any computer and printer, zoomable illustrations Binding Type Binding: N/A (Digital Download - no physical binding) Paper Type Paper Type: N/A (Digital Download - no physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder (specific displacement varies by model variant) Performance Horsepower Range: Estimated 30-40 HP (approximate, varies by model variant and tuning) Fuel System Fuel Delivery: Carbureted (400 models) and Electronic Fuel Injection (EFI) for DUSE, H.O., and RSE models. 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) with Hi/Low range and Reverse Optional Optional Transmissions: N/A for this model year and platform Features Transmission Features: Engine braking, belt-driven CVT system 📐 Dimensions Exterior Overall Length: Approximately 83 inches (210.8 cm) - varies slightly by model variant Overall Width: Approximately 46 inches (116.8 cm) Overall Height: Approximately 47 inches (119.4 cm) Weights Dry Weight: Approximately 600-650 lbs (272-295 kg) - varies by model variant Ground Clearance: Approximately 10.5 inches (26.7 cm) Towing Capacity: 1500 lbs (680 kg) Cargo Rack Capacity Front: 200 lbs (90.7 kg) Rack Capacity Rear: 400 lbs (181.4 kg) 🛡️ Safety Features Ratings Safety Certifications: N/A (ATVs typically don't have automotive crash ratings; manufacturer safety guidelines apply) Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Dual headlights, taillight, brake light Tire Specifications: Typically 25-inch AT tires; specific sizes vary by trim and tire manufacturer. 💡 Technology Features Infotainment Infotainment Features: Basic analog instrumentation (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems typical of modern vehicles. Driver Assistance Driver Assistance Systems: N/A (ATVs of this era did not feature advanced electronic driver aids). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 100 hours or 6 months, whichever comes first. (Consult manual for precise intervals) Spark Plug Replacement Interval: Every 12 months or 100 hours of operation. (Check manual for exact spec) Fluid Specifications Engine Oil Type: SAE 10W-40, API SG or higher. (Specific viscosity and API rating to be confirmed in manual) Coolant Type: Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Transmission Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent. Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Known Issues Common Wear Items: Drive belt wear, suspension bushings, wheel bearings, starter motor reliability (depending on usage). Electrical System Quirks: Wiring harness issues, stator failures (less common on EFI models but possible), voltage regulator. 📚 Vehicle History Brand Heritage Polarishistory: Polaris...