This manual covers All-Terrain Vehicles (ATVs) produced between 1996 and 2003, including the 400 and 500 models. The vehicle is recognized for its robust, torquey engines and reliable Variable Transmission system, offering a comfortable ride with independent front and MacPherson strut rear suspension. Known for its utility, the vehicle is well-suited for recreational riding, farm work, and light trail use, often featuring on-demand 4WD for enhanced traction. This comprehensive workshop service repair manual provides detailed information essential for maintaining and repairing your vehicle. It covers a wide array of systems including the engine, fuel, ignition, drive, suspension, braking, and electrical systems. You will find step-by-step repair procedures, overhaul instructions, troubleshooting guides, and crucial technical specifications such as torque settings and fluid capacities. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Model Variant: 400, 500 Vehicle Type: All-Terrain Vehicle (ATV) Codes Year Coverage: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Segment: Mid-size utility ATV, popular for recreational riding, farm work, and light trail use. Competitive Analysis Key Competitors: Honda Foreman, Yamaha Kodiak, Suzuki King Quad, Kawasaki Prairie Key Features Powertrain Emphasis: Known for its robust, torquey engines and reliable Polaris Variable Transmission (PVT) system. Handling And Comfort: Independent front suspension and MacPherson strut rear suspension offered good ride quality and handling for its class. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Likely 300-600+ pages (typical for complete workshop manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, component inspection, repair, overhaul, cylinder head, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system Fuel System: Carburetor (jetting, cleaning, rebuilding), fuel pump, fuel tank, fuel lines, fuel filter Ignition System: CDI unit, ignition coil, spark plug, stator, flywheel, timing Drive System: PVT (Polaris Variable Transmission) operation, belt replacement, clutch inspection and adjustment, chain drive (if applicable), differential, drive shafts, U-joints Suspension: Front and rear suspension geometry, shock absorber service, spring replacement, bushings, linkage maintenance Braking System: Hydraulic brake system, caliper service, master cylinder, brake lines, brake pads, rotors, bleeding procedures Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting system, switches, fuses, troubleshooting electrical faults Chassis And Frame: Frame inspection, body panel removal and installation, plastic components, seat assembly Steering: Steering linkage, tie rods, steering column, handlebars, bushings Cooling System: Radiator, fan, thermostat, coolant type, flushing and refilling procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, air filter cleaning/replacement, spark plug inspection, valve adjustment (if applicable) Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides Repair Procedures: Step-by-step instructions for component removal, installation, and repair Overhaul Procedures: Complete engine and transmission rebuild instructions Specification Data: Torque specifications, clearances, fluid capacities, performance data Wiring Diagrams: Comprehensive electrical schematics for fault finding and repair Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Detailed diagnostic procedures and specifications are expected. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically searchable text-based PDF for easy information retrieval Print Quality Print Readability: High quality, designed for clear printing of diagrams, text, and specifications. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, liquid-cooled, SOHC, 2-valve, single-cylinder Engine Displacement 400: Approx. 375cc (specific bore/stroke vary slightly by year, check manual for exact specs) Engine Type 500: 4-stroke, liquid-cooled, SOHC, 2-valve, single-cylinder Engine Displacement 500: Approx. 499cc (specific bore/stroke vary slightly by year, check manual for exact specs) Performance Horsepower Estimated: Approx. 25-30 HP (varies by model and specific year) Torque Estimated: Good low-end torque for pulling and climbing Fuel System Carburetor Type: Mikuni VM Series carburetor (e.g., VM34 or similar, specific to model/year) Fuel Type: Unleaded gasoline, 87 octane (minimum) Lubrication System Oil Type: SAE 10W-40 API SG or higher (check manual for exact specifications) Oil Capacity: Approx. 2.2 - 2.5 liters (with filter change, refer to manual for exact capacity) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic Drive Modes: 2WD/4WD selector, often with locking front differential Features Gear Selection: High, Low, Neutral, Reverse, Park Belt Drive System: Primary and secondary clutch system with drive belt Fluid Type Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant or equivalent (check manual for exact specifications) 📐 Dimensions Exterior Length: Approx. 81-83 inches (varies slightly by year) Width: Approx. 46 inches Height: Approx. 45-48 inches (varies slightly by year) Weights Dry Weight: Approx. 570-600 lbs (varies by model and year) Towing Capacity: Typically 1500 lbs Cargo Capacity Rear: Approx. 100 lbs Cargo Capacity Front: Approx. 50 lbs 🛡️ Safety...