🏷️ Basic Information

Make:

Polaris

Model:

Magnum 500

Year:

2002

Chassis Code Primary:

A02CD50AA

Chassis Code Rmk:

A02CD50AB

Chassis Code V Hds:

A02CD50FB

Generation Designation:

Second Generation Magnum

👋 Introduction

Atv Market Segment:

Mid-size to large displacement utility/recreational ATV, known for its robust performance and versatility in various terrains and tasks.

Competitive Landscape:

Competed against models from Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) in the early 2000s. The Magnum 500 was recognized for its powerful engine and comfortable ride.

Key Features Of Atv:

500cc liquid-cooled engine, automatic transmission with Hi/Lo range, shaft drive, independent front suspension (IFS), Polaris' proprietary anti-vibration system (VVC), robust rack systems for utility and storage.

📋 Manual Details

Manual Scope:

Comprehensive parts listing for 2002 Polaris Magnum 500 models, including standard, RMK, and 4x4 VL HDS variants.

Page Count:

64

Manual Type:

Parts Manual / Parts Catalog

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Frame, Bodywork, Engine Mounting, Cooling System, Exhaust System, Fuel System (Tank), Oil System (Tank), Air Intake System (Air Box), Front Drive System, Front Suspension (Struts, A-Arms), CV Joints, Front Wheels, Front Brakes, Steering System, Handlebars, Rear Drive System, Rear Suspension (Swing Arm, Shock), Drive Clutch, Driven Clutch, Clutch Housing, Gearcase, Drive Chain, Rear Brakes, Electrical System (including Taillight), Carburetor, Oil Pump, Magneto, Starting Motor, Recoil Starter, Tool Kit.

Procedures Included:

Component identification, part number referencing, assembly diagrams for various systems and sub-assemblies.

Technical Depth:

Detailed exploded views of all major components and sub-assemblies, enabling precise identification of individual parts and their relationships within the larger system. Focuses on part sourcing and assembly verification rather than diagnostic or repair procedures.

📊 Manual Specifications

File Format Details:

Portable Document Format (PDF). Optimized for digital viewing and selective printing.

Print Quality Ability:

Print only necessary pages for efficient printing and cost savings. Diagrams and part numbers are clearly rendered.

Binding Type:

N/A (Digital Download)

Paper Type Recommendation:

Standard printer paper for printed copies. Higher quality paper recommended for diagrams if frequent reference is needed.

⚙️ Engine Specifications

Engine Type:

4-stroke, Single Cylinder, Liquid-Cooled, SOHC

Engine Displacement:

499 cc

Bore X Stroke:

92 mm x 75.6 mm

Compression Ratio:

9.3:1

Claimed Horsepower:

Approx. 30-35 HP (Estimate based on era and class)

Fuel Delivery:

Carburetor

Carburetor Model:

Mikuni BSR42

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Oil Type:

SAE 20W-50 Motorcycle Oil (API SG or higher)

Oil Capacity:

2.3 US quarts (2.2 liters) with filter change

Cooling Medium:

Liquid (Ethylene Glycol based coolant)

Coolant Capacity:

Approx. 1.3 US quarts (1.2 liters)

Ignition System:

CDI (Capacitor Discharge Ignition)

Starting Method:

Electric Starter & Recoil Starter

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Gear Selection:

Forward (Hi/Lo), Neutral, Reverse

Drive System:

Shaft Drive

Drive Modes:

2WD/4WD (On-Demand)

Gearcase Oil Type:

Polaris Demand Drive Fluid or equivalent hypoid gear oil (SAE 80W-90)

Gearcase Oil Capacity:

200 ml (Front Gearcase)

📐 Dimensions

Length:

81.1 inches (2060 mm)

Width:

46 inches (1168 mm)

Height:

48 inches (1219 mm)

Dry Weight:

575 lbs (261 kg)

Ground Clearance:

11.25 inches (286 mm)

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Towing Capacity:

1500 lbs (680 kg)

Front Tire Size:

AT 25x8-12

Rear Tire Size:

AT 25x10-12

Wheel Bolt Pattern:

4/110 mm

🛡️ Safety Features

Lighting:

Dual Halogen headlights, Brake light, Taillight

Braking System:

Hydraulic Disc Brakes (Front and Rear)

Parking Brake:

Integrated into rear brake caliper

Engine Braking:

CVT provides inherent engine braking

Atv Safety Considerations:

As an ATV, it requires appropriate safety gear (helmet, eye protection, gloves, boots, long sleeves/pants) and responsible operation. Follow all warnings and instructions in the owner's manual.

💡 Technology Features

Infotainment Features:

N/A (Basic ATV design of the era, focus on functionality over entertainment features)

Driver Assistance Features:

N/A (Standard ATV operation)

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Every 100 hours or annually, whichever comes first. Check owner's manual for specific recommendations.

Spark Plug Replacement:

Recommended every 300 hours or as needed. Consult manual for correct spark plug type (e.g., NGK CR9EB).

Air Filter Cleaning Replacement:

Inspect every 50 hours, clean or replace as needed. Crucial for engine longevity.

Fuel Filter Replacement:

Inspect and replace as needed, typically during annual service. Fuel filter part number often found in the manual.

Coolant Flush Replacement:

Every 2 years or 200 hours. Use a 50/50 mix of ethylene glycol coolant and distilled water.

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

CV boots, wheel bearings, brake pads, drive belts (CVT), ball joints, tie rod ends.

Potential Reliability Concerns:

Early model CVTs could sometimes exhibit premature belt wear if operated excessively under heavy load or without proper warm-up/cool-down. Cooling system components (hoses, radiator) can also be a point of maintenance.

Parts Manual Utility:

Essential for accurately identifying correct replacement parts, ensuring proper fitment and function, thus avoiding costly mistakes and downtime. Helps in understanding assembly order for complex components like clutches and gearcases.

📚 Vehicle History

Polaris Atv History:

Polaris has a long-standing reputation for producing innovative and capable ATVs, starting with the early Trail Boss models. They are known for introducing many industry firsts.

Magnum Series Evolution:

The Magnum 500 was part of Polaris's popular Magnum line, which evolved from earlier models, focusing on power, comfort, and utility. The 2002 model benefited from several years of refinement.

Manufacturing Location:

Roseau, Minnesota, USA (Typical for Polaris ATVs)

🏆 Awards & Recognition

Atv Industry Awards:

Polaris ATVs of this era frequently received praise in industry publications for performance, handling, and utility features. Specific awards for the 2002 Magnum 500 might be found in archived ATV magazines.