Polaris Sportsman 400 450 500 WSM 1996-2013 ATV Service Repair Manual 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2012 2013

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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...

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Typ: Atv

Anbieter:

Art.-Nr: 88088

Stichworte: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 Atv Browning Guns Firearms Weapons Home and Garden Polaris Sporting Goods Sportsman 400 Sportsman 450 Sportsman 500

Produktvarianten

Beschreibung

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:

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:

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 gauge, and indicator lights. No advanced infotainment systems.

Driver Assistance

Driver Assistance Features:

All-Wheel Drive (AWD) engagement, engine braking (through PVT).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 12 months, whichever comes first.

Air Filter Inspection:

Every 25 hours, clean or replace as needed.

Spark Plug Inspection:

Every 100 hours or 12 months.

Drive Belt Inspection:

Every 100 hours; inspect for wear, cracks, and damage.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 (SAE 5W-50) Synthetic Ester Oil or equivalent API SG, JASO MA certified oil.

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent (for final drive and transmission).

Coolant Type:

Polaris Coolant (50/50 mix of ethylene glycol and distilled water)

Known Issues

Common Issues Overview:

Early models may experience drive belt wear, starter solenoid issues, and potential charging system problems. EFI system diagnostics and fuel injector cleaning are common maintenance tasks. Suspension wear and tear are also typical for this age range.

Efi System Considerations:

Requires diagnostic tools for advanced troubleshooting of fuel delivery and sensor issues.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Polaris has a long-standing reputation for innovation and durability in the powersports industry, particularly with its Sportsman line of ATVs.

Model Evolution

Model Evolution:

The Sportsman line has been a cornerstone for Polaris, evolving through various engine sizes and technological updates like the introduction of EFI and AWD systems.

Production

Production Period:

1996-2013 for the specific models covered by this manual.

🏆 Awards & Recognition

Recognitions

Atv Industry Recognition:

Polaris Sportsman series consistently recognized for utility and off-road capability by industry publications and consumer reviews.

Certifications

Manual Certification:

Official Polaris OEM documentation