Target Audience:
Written for 2002 Polaris Sportsman 400-500 dealership mechanics, indicating a professional-grade resource.
Value Proposition:
Provides the essential information to service, repair, and maintain the vehicle, ensuring reliability and longevity.
Manual Advantage:
Reprint of the original dealer manual, offering authoritative and accurate information directly from the manufacturer's recommended procedures.
Content Highlight:
Step-by-step instructions, clear pictures, exploded view illustrations, schematics, and specifications.
Overall Benefit:
Enables users to 'get your project on the road and keep it there' by providing comprehensive repair and maintenance guidance.
Primary Coverage:
Comprehensive repair and service for 2002 Polaris Sportsman 400 and 500 models.
Secondary Coverage:
Troubleshooting, diagnostics, maintenance, and component overhaul.
Estimated Page Count:
While not explicitly stated, typical dealership-level workshop manuals of this era for ATVs are extensive, likely ranging from 500 to 1000+ pages, given the depth of coverage.
Type:
Workshop Repair Service Manual
Digital Format:
PDF Download
Compatibility:
All Versions of Windows, Mac, iOS, BlackBerry, Android, etc.
Engine Mechanical:
Complete engine overhaul and rebuilding, including disassembly, inspection, repair, and reassembly of all internal components.
Engine Performance:
Engine performance tuning, troubleshooting, and specifications.
Fuel System:
Carburetor specifications, cleaning, adjustment, and troubleshooting. Fuel pump operation and testing.
Ignition System:
Ignition timing, spark plug specifications, coil testing, and troubleshooting.
Cooling System:
Radiator, fan, thermostat, and coolant specifications. Bleeding and flushing procedures.
Exhaust System:
Muffler, pipe, and heat shield inspection and replacement.
Drivetrain:
Transmission removal and installation, in-car servicing, and troubleshooting. CV-joint and U-joint service procedures.
Suspension:
Front end alignment procedures and specifications, shock absorber service, and suspension component replacement.
Brakes:
Brake servicing procedures, including caliper, rotor, and master cylinder repair. Brake bleeding and fluid specifications.
Electrical System:
Complete wiring diagrams, troubleshooting electrical concerns, starter, charging system, battery specifications, and lighting.
Bodywork:
Body panel removal and installation, seat removal, and general exterior component servicing.
Controls:
Handlebar, throttle, and brake lever adjustments and service.
Heating Ventilation Air Conditioning:
Air conditioning service and capacities (if applicable to specific trims).
Major Repair:
Complete engine overhaul and rebuilding, transmission removal and installation, brake system overhaul.
Routine Maintenance:
Factory maintenance schedules and charts, fluid changes, filter replacements, and lubrication.
Troubleshooting:
Step-by-step troubleshooting guides for common and complex issues, including diagnostic trouble codes.
Diagnostics:
Computer diagnostic trouble tree charts and procedures.
Timing Belt:
Timing belt replacement service procedures.
Alignment:
Front end and alignment procedures and specifications.
Belt Routing:
Serpentine belt routings with diagrams.
U Joint Cv Joint:
U-joint and CV-joint service procedures.
Driving Concerns:
Addressing common driving concerns and solutions.
Depth:
Dealership-level comprehensive coverage, suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed specifications, diagrams, and step-by-step instructions for complex repairs and overhauls.
Illustrations:
Hundreds of illustrations, including clear pictures and exploded view illustrations for easy identification of parts and assembly.
Schematics:
Detailed schematics for various systems.
Specifications:
Detailed specifications on every model covered, including complete torque specifications.
Engine Type:
The manual covers both 400cc and 500cc variants, typically single-cylinder, liquid-cooled, four-stroke engines.
Horsepower Range:
Approximate horsepower for the 2002 Sportsman 400 was around 25-30 HP, and for the 500 model, around 30-35 HP. Exact figures would be in the manual.
Torque Specifications:
Complete torque specifications for all engine components are included.
Carburetor Details:
Detailed specifications and service procedures for the carburetor(s) used on both 400 and 500 models.
Firing Orders:
Firing orders are explicitly mentioned as being covered.
Timing Belt Coverage:
Covers timing belt replacement service procedures. Note: Many Polaris ATVs of this era used timing chains, not belts. The manual will clarify which system is present and how to service it.
Length Width Height:
Specific dimensions for the 2002 Sportsman models are detailed in the manual, typically around 81x46x47 inches (LWH).
Dry Weight:
Dry weight for the Sportsman 400 was around 580 lbs, and for the 500, around 600 lbs. Exact figures will be in the manual.
Towing Capacity:
Likely rated for a towing capacity of 1500 lbs, as is common for these models.
Tire Size Front:
Typically 25x8-12 or similar.
Tire Size Rear:
Typically 25x10-12 or similar.
Wheel Bolt Pattern:
Standard ATV bolt patterns, usually 4x110mm or similar, will be specified.
Oil Change Interval:
The manual will provide specific mileage or hours-based intervals for engine oil and filter changes, likely around 100 hours or annually.
Air Filter Maintenance:
Schedule for cleaning or replacing the air filter based on operating conditions.
Spark Plug Replacement:
Recommended intervals for spark plug inspection and replacement.
Engine Oil Type:
The manual will specify the SAE viscosity grade (e.g., 5W-50, 10W-40) and API service classification for engine oil.
Coolant Type:
Specification for the recommended antifreeze/coolant mixture (e.g., ethylene glycol-based) and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid specification.
Common Problems 2002 Sportsman:
While specific known issues are best diagnosed with the manual, common points of attention for this era of Sportsman might include starter motor issues, fuel pump reliability, and occasional CVT belt wear. The manual provides the definitive troubleshooting for these.
