Polaris Sportsman 400 500 DUSE & H.O. ATV Complete Workshop Service Repair Manual 2001 2002

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This manual covers the All-Terrain Vehicle (ATV) models from 2001 and 2002, including the 400, 500 DUSE, and 500 H.O. variants. The is recognized for its robust engineering, offering a...

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Taper: Atv

Distributeur:

UGS: 94514

Mots clés: 2001 2002 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500

Variantes de produits

Description

This manual covers the All-Terrain Vehicle (ATV) models from 2001 and 2002, including the 400, 500 DUSE, and 500 H.O. variants. The is recognized for its robust engineering, offering a blend of utility and recreational capability. These ATVs are designed for a variety of terrains and tasks, from trail riding to hauling, and are known for their reliable engines, independent front suspension, and automatic transmission with all-wheel-drive engagement. The 500 H.O. models, in particular, offer enhanced performance with their high-output engines. This comprehensive workshop service repair manual provides detailed information essential for the maintenance and repair of your. It covers all major systems, including the engine, fuel, ignition, transmission, drivetrain, cooling, electrical, braking, suspension, steering, bodywork, chassis, and exhaust. Within these sections, you will find step-by-step repair instructions, diagnostic procedures, troubleshooting guides, and critical technical specifications such as torque values and fluid capacities. This manual is an invaluable resource for owners and technicians seeking to ensure the longevity and optimal performance of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman

Model Variant:

400, 500 DUSE, 500 H.O.

Model Year:

2001, 2002

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Vehicle Segment:

Entry-level to mid-range utility ATV.

Competitive Analysis

Key Competitors:

Honda FourTrax, Yamaha Wolverine, Suzuki King Quad.

Key Features

Powertrain:

Known for reliable Polaris engines, particularly the 500cc HO variant.

Suspension:

Independent front suspension (IFS) and swingarm rear suspension (on most models) offering good comfort and capability.

Utility:

Designed for work and recreational trail riding, with rack capacity for hauling.

Manual Value Proposition

Diy Capability:

Enables owners to perform a wide range of maintenance and repair tasks themselves, saving on labor costs.

📋 Manual Details

Coverage Areas

Coverage Type:

Complete Workshop Service Repair

Page Count

Estimated Page Count:

Refer to manual for exact count

Manual Type

Manual Format:

Downloadable PDF

Language

Language:

English

Format

File Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, overhaul, troubleshooting for 400cc and 500cc engine variants.

Fuel System:

Carburetor service, fuel pump, fuel lines, fuel tank maintenance, troubleshooting.

Ignition System:

Spark plug service, ignition coil testing, CDI unit diagnosis, stator and rotor inspection.

Transmission Drivetrain:

CVT (Continuously Variable Transmission) belt inspection and replacement, clutch service, gearbox maintenance, driveshaft and U-joint checks.

Cooling System:

Radiator service, fan operation, thermostat replacement, coolant flush procedures.

Electrical System:

Battery testing and maintenance, starter motor, charging system (alternator/stator), lighting, wiring diagrams, switch operation, fuse replacement.

Braking System:

Brake pad replacement, caliper service, brake fluid bleeding, master cylinder inspection, brake line maintenance.

Suspension Steering:

Front and rear suspension component inspection and replacement, shock absorber service, steering linkage, tie rod ends, wheel alignment procedures.

Bodywork Chassis:

Frame inspection, plastic panel removal and installation, seat maintenance, handlebars, fenders, racks.

Exhaust System:

Muffler and exhaust pipe inspection, gasket replacement, heat shield maintenance.

Procedures Included

Maintenance:

Routine service, oil changes, filter replacements, lubrication points, general inspection checks.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common issues.

Repair:

Step-by-step instructions for component replacement and repair.

Rebuilds:

Detailed procedures for engine and transmission overhauls.

Technical Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values.

Technical Depth

Diagnostic Capabilities:

Comprehensive diagnostic procedures for all major systems, including electrical and mechanical components.

Repair Complexity:

Covers basic maintenance to complete engine and transmission rebuilds.

Wiring Diagrams:

Includes detailed electrical system wiring diagrams for troubleshooting and component identification.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Searchability

Text Search:

Searchable text for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type 400:

4-stroke, liquid-cooled, single-cylinder.

Engine Type 500:

4-stroke, liquid-cooled, SOHC, single-cylinder.

Displacement 400:

Approximately 375cc (specific for 400 models of this era).

Displacement 500:

Approximately 499cc (specific for 500 models of this era).

Performance

Horsepower Estimate 400:

Estimated 25-30 HP range.

Horsepower Estimate 500 Ho:

Estimated 30-35 HP range (HO - High Output).

Fuel System

Carburetion 400:

Mikuni or Keihin carburetor (specific size varies).

Carburetion 500:

Mikuni or Keihin carburetor (specific size varies, often larger for HO).

Cooling System

Cooling Method:

Liquid-cooled with a fan assist.

Lubrication

Oil Type Specification:

SAE 5W-50 Synthetic or 10W-40 (Refer to manual for exact Polaris recommendation).

🔧 Transmission

Standard

Transmission Type:

Automatic with Polaris Variable Transmission (PVT) and Engine Braking.

Optional

Transmission Options:

N/A (Standard automatic CVT).

Features

Drive Modes:

2WD/4WD selector with AWD (All-Wheel Drive) engagement.

Gear Selection:

High, Low, Neutral, Reverse, Park.

Fluid Type

Transmission Fluid Spec:

Polaris PVT Fluid (or equivalent like AGL Synthetic Gearcase Lubricant for specific components).

📐 Dimensions

Exterior

Length:

Approx. 81 inches (2057 mm).

Width:

Approx. 46 inches (1168 mm).

Height:

Approx. 47 inches (1194 mm).

Weights

Dry Weight:

Approx. 600-650 lbs (272-295 kg).

Ground Clearance:

Approx. 10.5 inches (267 mm).

Cargo

Rack Capacity Front:

Approx. 90 lbs (41 kg).

Rack Capacity Rear:

Approx. 170 lbs (77 kg).

Towing

Towing Capacity:

1500 lbs (680 kg).

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet industry safety standards for ATVs.

Active Features

Engine Braking:

Provides deceleration assistance when throttle is released.

Awt System:

Automatic All-Wheel Drive engagement for enhanced traction.

Passive Features

Handlebars:

Handlebar design optimized for control and rider comfort.

Brakes:

Hydraulic disc brakes front and rear for reliable stopping power.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility vehicle, no advanced infotainment).

Driver Assistance

Driver Assistance Features:

None (Standard ATV features like AWD).

Connectivity

Connectivity Features:

N/A (No digital connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 100 hours or annually, whichever comes first (Refer to manual for specific mileage/hours).

Air Filter Cleaning:

Check and clean every 20-30 operating hours, replace as needed.

Spark Plug Replacement:

Recommended every 1000 hours or as needed, depending on condition.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Wear Items:

CVT belt, suspension bushings, ball joints, and starter solenoids can be common wear items on higher mileage units.

Electrical Connections:

Corrosion on electrical connectors can sometimes cause intermittent issues.

📚 Vehicle History

Brand Heritage

Polaris Atv Legacy:

Polaris has a long history of manufacturing ATVs, being one of the pioneers in the industry.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort and versatility.

Production

Manufacturing Location:

Primarily manufactured in the USA by Polaris Industries.

Model Year Context

2001 2002 Features:

These model years represented a mature and well-received generation of the Sportsman, building on previous iterations.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Polaris Sportsman models have consistently received positive reviews for their performance and utility in the ATV market.