This manual covers ATVs, including the 400, 450, and 500cc EFI models, produced between 1996 and 2013. These versatile 4x4 ATVs are renowned for their capability in trail riding, utility work, and recreational activities. The brand has a strong heritage in powersports, with the Sportsman line consistently recognized for its durability and off-road performance, enhanced by technological advancements such as Electronic Fuel Injection (EFI) and All-Wheel Drive (AWD) systems. This comprehensive 626-page Workshop Service Manual (WSM) provides detailed, official documentation essential for maintaining and repairing your Sportsman ATV. It covers all major systems, including engine, drivetrain, chassis, suspension, steering, brakes, and electrical systems, with step-by-step instructions for diagnostics, maintenance, and overhauls. The manual is designed to assist owners and technicians in ensuring the optimal performance and longevity of their vehicle through accurate procedures and detailed diagrams. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400, 450, 500 Product Type: ATV Service Repair Manual Codes Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2012, 2013 Engine Variants Covered: 400cc, 450cc, 500cc (EFI models only, excluding 500 ATP HO) 👋 Introduction Market Position Market Position: Essential tool for Polaris Sportsman owners and independent repair shops focused on ATV maintenance and repair. Competitive Analysis Competitive Advantage: Official Polaris documentation ensures accuracy and completeness, surpassing generic aftermarket repair guides. Key Features Key Features Manual: Official WSM, 626 pages, covers multiple engine displacements and years, instant PDF download, detailed diagrams, part numbers included. Key Features Vehicle: Versatile 4x4 ATVs known for trail riding, utility work, and recreational use. Strong emphasis on EFI systems for improved performance and emissions. 📋 Manual Details Coverage Areas Geographic Coverage: Global (based on Polaris standard specifications) Page Count Page Count: 626 Manual Type Manual Type: Workshop Service Manual (WSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, lubrication, cooling, fuel injection, ignition, starting system, exhaust system Drivetrain Systems: Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt maintenance, final drive, AWD system (if applicable) Chassis Suspension Steering: Frame, front and rear suspension, shocks, A-arms, steering system, tie rods, wheel bearings Braking Systems: Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake discs Electrical Systems: Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting, starter motor, ignition switch, fuses, relays, diagnostic codes Fuel Systems: Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, EFI control module (ECU) Body Components: Body panels, fenders, seat, handlebars, racks Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, spark plug inspection/replacement, drive belt inspection/replacement, fluid level checks and top-offs Diagnostic Procedures: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all major systems Overhaul Procedures: Engine overhaul, transmission rebuild, suspension component replacement Adjustment Procedures: Carburetor/throttle body synchronization, valve adjustments (if applicable), brake adjustments Technical Depth Technical Depth: Comprehensive: Covers routine maintenance to complete engine and drivetrain rebuilds, including electrical system diagnostics. Detail Level: Detailed with exploded views and diagrams for precise component identification and reassembly. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Zoom-able illustrations, high-resolution diagrams Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchability: Searchable text for quick access to information Licensing Licensing: Downloadable for unlimited personal use; can print multiple copies ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-Cooled, Single Cylinder (specific configuration varies by model year and displacement) Bore X Stroke: Varies by displacement (e.g., 92mm x 76.5mm for 500cc) Displacement: 400cc, 450cc, 500cc Performance Horsepower: Typically in the range of 25-34 HP (varies by model and year) Torque: Varies by displacement and engine tuning Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (91 octane recommended) Ignition Ignition System: CDI with electronic advance 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic Optional Gear Selection: High, Low, Neutral, Reverse Features Drive System: Shaft Drive, All-Wheel Drive (AWD) with ADC (Active Descent Control) on some models 📐 Dimensions Exterior Wheelbase: Approx. 50.5-50.9 inches (varies slightly by model year) Ground Clearance: Approx. 10-11 inches (varies by model year and suspension) Weights Dry Weight: Approx. 600-675 lbs (varies by model) Towing Capacity: Typically 1500 lbs Rack Capacity Front: Typically 100 lbs Rack Capacity Rear: Typically 200 lbs 🛡️ Safety Features Ratings Atv Safety Standards: Compliant with ANSI/SVIA standards where applicable. Active Features Braking System Type: Hydraulic disc brakes, sealed driveline AWD System Features: Automatic engagement of front drive wheels when rear wheels lose traction (on AWD models) Passive Features Rollover Protection: N/A (ATVs are designed for off-road use and require operator awareness; no ROPS typically unless specified for specialized models). 💡 Technology Features Infotainment Infotainment System: Basic; typically a digital odometer, fuel...