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.
Engine Variant Codes:
DUSE, H.O. (High Output), RSE
Vehicle Segment:
Heavy-duty All-Terrain Vehicle (ATV), utility and recreational
Key Competitors 2002:
Yamaha Wolverine, Arctic Cat 500, Honda Foreman, Kawasaki Bayou
Atv Attributes:
Known for robust build, versatility for work and trail riding, independent rear suspension (IRS) on some models, strong engine performance.
Specific Models Covered:
Polaris Sportsman 400, Polaris Sportsman 500 DUSE, Polaris Sportsman 500 H.O., Polaris Sportsman 500 RSE
Estimated Page Count:
Variable (typically 300-500 pages for comprehensive ATV manuals, exact count not specified in product info)
Type:
Service Repair Manual (Factory/Workshop Equivalent)
Language:
English (implied by product description and typical market for these vehicles)
Delivery Format:
PDF Download
Major Systems:
General Information, Specifications, Periodic Checks & Adjustments, Chassis, Engine, Cooling System, Fuel Injection System, Electrical System
Repair And Maintenance:
Troubleshooting, Repair, Service, Restoration, Rebuilding, Diagnostics, Preventative Maintenance
Diagnostic And Rebuild Capabilities:
Detailed step-by-step instructions for complex repairs, diagnostics, and rebuilds; suitable for professional technicians and DIY enthusiasts.
Digital Format:
PDF (requires PDF reader, may be zipped requiring WinZip/WinRAR)
Printability:
Printable on any computer and printer, zoomable illustrations
Binding:
N/A (Digital Download - no physical binding)
Paper Type:
N/A (Digital Download - no physical paper type)
Engine Type:
Four-stroke, liquid-cooled, single-cylinder (specific displacement varies by model variant)
Horsepower Range:
Estimated 30-40 HP (approximate, varies by model variant and tuning)
Fuel Delivery:
Carbureted (400 models) and Electronic Fuel Injection (EFI) for DUSE, H.O., and RSE models.
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with Hi/Low range and Reverse
Optional Transmissions:
N/A for this model year and platform
Transmission Features:
Engine braking, belt-driven CVT system
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)
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)
Rack Capacity Front:
200 lbs (90.7 kg)
Rack Capacity Rear:
400 lbs (181.4 kg)
Safety Certifications:
N/A (ATVs typically don't have automotive crash ratings; manufacturer safety guidelines apply)
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Dual headlights, taillight, brake light
Tire Specifications:
Typically 25-inch AT tires; specific sizes vary by trim and tire manufacturer.
Infotainment Features:
Basic analog instrumentation (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems typical of modern vehicles.
Driver Assistance Systems:
N/A (ATVs of this era did not feature advanced electronic driver aids).
Connectivity Features:
N/A
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)
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.
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.
Polarishistory:
Polaris Industries is a long-standing American manufacturer known for snowmobiles, ATVs, and side-by-side vehicles, established in 1954.
Sportsman Line History:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from utilitarian models to feature-rich, high-performance machines. The 2002 models represent a significant development with the introduction of fuel injection on higher-end variants and the continuation of the IRS system.
Manufacturing Location:
Primarily manufactured in Roseau, Minnesota, USA, and Spirit Lake, Iowa, USA.
Industry Awards:
While specific awards for the 2002 Sportsman 400/500 aren't typically highlighted, the Sportsman line has consistently been recognized for its utility, performance, and reliability within the ATV industry.
