🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400/500 ATV

Year:

2002

Product Name:

2002 Polaris Sportsman 400 500 ATV Repair Manual Download PDF

Sku:

Not Specified

👋 Introduction

Market Position:

Targeted at owners and technicians of 2002 Polaris Sportsman 400 and 500 4x4 ATVs, providing essential factory-level repair and maintenance information.

Competitive Analysis:

Offers OEM-quality information, distinguishing itself from generic or aftermarket repair guides by providing factory-authorized content.

Key Features:

Comprehensive coverage, instant digital access, printable format, lifetime replacement policy, factory-authorized content.

📋 Manual Details

Covered Models:

2002 Polaris Sportsman 400 4x4 ATV, 2002 Polaris Sportsman 500 DUSE 4x4 ATV, 2002 Polaris Sportsman 500 HO 4x4 ATV, 2002 Polaris Sportsman 500 RSE 4x4 ATV

Coverage Areas:

General Information, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting

Format:

Digital Downloadable PDF

Delivery Method:

Instant Download

Language:

English

Manual Type:

OEM Shop, Service, Repair, Owner's Manual, Parts Catalog (information varies per manual)

Source Type:

OEM Manuals and Factory Authorized Reprints

📖 Manual Coverage

Systems Covered:

Engine (including removal/installation, lubrication, cooling, fuel), Transmission, Drive Chain & Sprockets, Steering System, Suspension (Shocks), Electrical System, Body Work, Intake System, Exhaust System

Procedures Included:

Routine Maintenance, Engine Repair, Fuel System Servicing, Lubrication Procedures, Cooling System Maintenance, Transmission Servicing, Drive Component Maintenance, Steering System Repair, Shock Absorber Service, Body Panel Repair, Intake and Exhaust System Maintenance, Electrical System Diagnostics and Repair, Troubleshooting of Common Issues

Technical Depth:

Comprehensive factory-level repair and maintenance procedures suitable for DIY mechanics and professional technicians. Includes detailed diagrams, specifications, and troubleshooting guides.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely searchable text within the PDF, allowing for quick access to specific topics.

Print Quality:

Printable pages, allowing users to print specific sections as needed.

Availability:

Instant download post-payment.

Support Policy:

Lifetime Protection Policy: Free replacement if lost or damaged.

⚙️ Engine Specifications

Engine Type:

4-stroke

Engine Configuration:

Single-cylinder (for 400 model), Twin-cylinder (for 500 models)

Displacement:

375cc (for 400 model), 499cc (for 500 models)

Horsepower:

Approximately 27 hp (400 model), Approximately 33 hp (500 models) - estimates based on typical specs for the era.

Torque:

Details vary by specific model, typically in the range of 25-30 lb-ft for the 400 and 30-35 lb-ft for the 500.

Fuel Delivery:

Carbureted (likely Mikuni BST series, specific model dependent)

Fuel Type:

Unleaded Gasoline

Cooling Method:

Liquid-cooled

Oil Type Recommendation:

API SG/SH/SJ classification, SAE 10W-40 or 20W-50 viscosity (refer to specific manual for exact spec).

Engine Codes:

Specific engine serial numbers would be detailed within the manual, typically starting with 'C8'.

🔧 Transmission

Drive Type:

4x4 AWD (All-Wheel Drive)

Transmission Type:

Automatic (Polaris Variable Transmission - PVT with Engine Braking)

Transmission Features:

High/Low range, Neutral, Reverse. Features engine braking in all forward gears.

Transmission Fluid Type:

Polaris Synthetic 1W-50PS or equivalent PVT fluid. (Crucial to verify with manual)

📐 Dimensions

Length:

Approx. 83 inches

Width:

Approx. 46 inches

Height:

Approx. 47 inches

Dry Weight:

Approx. 650-700 lbs (model dependent)

Ground Clearance:

Approx. 11 inches

Rack Capacity Front:

200 lbs

Rack Capacity Rear:

400 lbs

Towing Capacity:

1500 lbs

🛡️ Safety Features

Active Features:

Full-time 4WD, Engine Braking, Disc Brakes front and rear.

Passive Features:

Handgrips, Integrated Headlight and Taillight, Footwells.

Atv Safety Standards:

The manual will cover procedures to maintain the ATV in compliance with relevant safety standards of the time, though specific ratings are not typical for ATVs in the same way as cars.

💡 Technology Features

Infotainment Features:

Basic instrumentation: speedometer, odometer, fuel gauge, indicator lights. No advanced infotainment features.

Driver Assistance Features:

Full-time AWD system is the primary driver assistance feature for traction.

Lighting System:

Dual Halogen headlights, LED taillight/brakelight.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or annually, whichever comes first (refer to manual for exact timing).

Air Filter Maintenance:

Inspect every 20 hours, clean/replace as needed, especially in dusty conditions.

Spark Plug Replacement:

Recommended every 100-200 hours or annually.

Brake Fluid Flush:

Recommended every 2 years or as per manual instructions.

Engine Oil Capacity:

Approx. 2.0-2.5 quarts (refer to manual for exact capacity).

Coolant Type:

Ethylene glycol-based antifreeze mixture (50/50 with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Issues:

Potential issues may include CV joint wear, starter solenoid problems, carburetor tuning difficulties, and PVT belt wear. The manual provides diagnostic and repair procedures for these and other common concerns.

📚 Vehicle History

Brand Heritage:

Polaris has a long history in powersports, known for innovation in ATVs and snowmobiles since its founding in 1954.

Model Evolution:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, continuously evolving in engine size, features, and capabilities. The 2002 models represent a mature iteration of the popular large-bore utility ATV platform.

Production Location:

Polaris vehicles are primarily manufactured in the United States, at facilities like their main plant in Roseau, Minnesota.

🏆 Awards & Recognition

Recognitions:

The Polaris Sportsman line has consistently received positive reviews and is widely recognized for its durability and performance in the utility ATV segment. Specific awards for the 2002 model may vary but it was a segment leader.