Category:
All-Terrain Vehicle (ATV)
Target User:
Recreational riders, utility users, and DIY mechanics.
Key Competitors Era:
Honda FourTrax, Yamaha Kodiak, Suzuki King Quad.
Vehicle Focus:
Rugged utility, reliable performance for varied terrain.
Manual Value:
Essential for maintaining optimal performance and longevity of the vehicle.
Primary Coverage:
Comprehensive service and repair for Polaris Sportsman 400 and 500 models.
Specific Systems:
Engine, transmission, drivetrain, suspension, brakes, electrical system, fuel system, cooling system, bodywork, chassis.
Estimated Page Count:
Over 300 pages (typical for comprehensive service manuals of this era).
Type:
Service Repair Manual
Format:
Digital Download (PDF)
Engine Overhaul:
Detailed procedures for engine disassembly, inspection, repair, and reassembly.
Transmission Service:
Information on transmission operation, troubleshooting, and repair for automatic/CVT systems.
Drivetrain Maintenance:
Coverage of front and rear differentials, driveshafts, and U-joints.
Suspension And Steering:
Procedures for inspecting, repairing, and adjusting front and rear suspension components and steering systems.
Brake System Repair:
Details on hydraulic brake systems, including caliper, master cylinder, and bleeding procedures.
Electrical Diagnostics:
Wiring diagrams, troubleshooting guides for ignition, charging, lighting, and accessories.
Fuel System Troubleshooting:
Carburetor service, fuel pump operation, and fuel line maintenance.
Cooling System Service:
Radiator, fan, thermostat, and coolant maintenance procedures.
Bodywork And Chassis:
Information on body panel removal, frame inspection, and component mounting.
Routine Maintenance:
Oil changes, filter replacements, lubrication, and general inspections.
Troubleshooting Guides:
Diagnostic flowcharts and symptom-based problem-solving for common issues.
Component Replacement:
Step-by-step instructions for replacing major and minor components.
Rebuilding Procedures:
Detailed instructions for rebuilding engine components, carburetors, and differentials.
Torque Specifications:
Precise torque values for all critical fasteners.
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostics:
Advanced diagnostic procedures and troubleshooting for electrical and mechanical systems.
Special Tools:
Identification of specific tools required for certain repair procedures.
Engine Type:
4-stroke, Liquid-Cooled, SOHC
Displacements:
375cc (Sportsman 400), 499cc (Sportsman 500)
Bore X Stroke 400:
82mm x 71.2mm (approximate, refer to manual for exact)
Bore X Stroke 500:
92mm x 71.2mm (approximate, refer to manual for exact)
Compression Ratio:
Typically around 8.4:1 or 9.0:1 (check manual for specific variant)
Horsepower 400:
Approx. 24-28 HP (refer to manual for exact)
Horsepower 500:
Approx. 30-34 HP (refer to manual for exact)
Fuel Delivery:
Carbureted (Mikuni VM34SS or similar for 500, smaller for 400)
Fuel Type:
Unleaded Gasoline, 87 Octane (minimum)
Fuel Capacity:
Typically around 3.4 - 3.7 gallons (13-14 liters)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range
Gearbox:
Not Applicable (CVT is standard)
Drive Modes:
2WD/4WD selector, Engine Braking
Transmission Fluid Type:
Polaris AGL or equivalent (refer to manual for precise spec and capacity)
Length:
Approx. 81-83 inches (206-211 cm)
Width:
Approx. 46-48 inches (117-122 cm)
Height:
Approx. 48-50 inches (122-127 cm)
Wheelbase:
Approx. 50-52 inches (127-132 cm)
Dry Weight:
Approx. 550-650 lbs (250-295 kg)
Towing Capacity:
Typically rated at 1,500 lbs (680 kg)
Rack Capacity Front:
Typically around 90 lbs (41 kg)
Rack Capacity Rear:
Typically around 180 lbs (82 kg)
Classification:
All-Terrain Vehicle (ATV) - Off-road use only.
Braking System:
Hydraulic disc brakes (front and rear).
Parking Brake:
Mechanical parking brake, often integrated with transmission or caliper.
Lighting:
Dual headlights, taillight/brake light.
Operator Safety:
Thumb throttle for controlled acceleration, hand brake levers.
Features:
Basic instrument cluster: speedometer, odometer, fuel gauge, warning lights.
Features:
N/A (No electronic driver-assistance systems in this era of ATVs).
Features:
N/A (No integrated connectivity features).
Engine Oil Change:
Every 100 hours or annually (refer to manual for exact hours/mileage).
Air Filter Cleaning Replacement:
Inspect every 25 hours, clean/replace as needed.
Spark Plug Inspection Replacement:
Inspect every 100 hours, replace as needed.
Transmission Fluid Change:
Every 200 hours or annually (refer to manual for exact).
Engine Oil Type:
SAE 10W-40 (API SG or higher rated)
Engine Oil Capacity:
Approximately 2.0 - 2.5 quarts (1.9 - 2.4 liters), check dipstick.
Coolant Type:
Ethylene Glycol-based antifreeze, 50/50 mix with distilled water.
Common Wear Items:
Drive belts (CVT), tie rod ends, wheel bearings, brake pads.
Potential Electrical Issues:
Stator or voltage regulator failure, corroded connections.
Carburetor Maintenance:
Can be prone to clogging if fuel is not fresh or if stored improperly.
Manufacturer:
Polaris Industries Inc., established in 1954, known for powersports vehicles.
Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from earlier models into more capable and feature-rich machines.
2001-2002 Context:
These model years represent a period of significant development in ATVs, with increased engine sizes and improved suspension systems becoming more common.
Manufacturing Location:
Polaris manufacturing facilities (primarily USA).
