Target Audience:
Owners of 2002 Polaris Sportsman 400 seeking to perform maintenance, repairs, or diagnostics.
Value Proposition:
Provides factory-level technical data and procedures, enabling cost-effective DIY repairs and maintenance, ensuring optimal vehicle performance and longevity.
Ease Of Use:
Described as a handy, easy-to-read reference book with sequentially ordered steps.
Comprehensiveness:
Covers all installation, removal, disassembly, assembly, repair, and check procedures.
Systems Covered:
Engine, transmission, drivetrain, chassis, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, bodywork, and troubleshooting.
Page Count:
Actual page count not specified in product information. Typical factory service manuals for this era range from 300-600 pages.
Manual Type:
Factory Service Repair Manual
Language:
English (assumed for North American market, typical for Polaris manuals)
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly of all internal engine components including cylinder head, pistons, crankshaft, camshaft, valves, timing components, and lubrication system.
Engine Fuel System:
Carburetor (model specific, likely Mikuni) adjustment, cleaning, and rebuilding; fuel pump operation and testing; fuel tank and lines.
Cooling System:
Radiator, fan, water pump, thermostat, and coolant flow diagnostics and maintenance.
Exhaust System:
Muffler, exhaust pipes, and heat shields; inspection for leaks and damage.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) operation, belt inspection and replacement, clutch assembly servicing, gearbox maintenance, and driveshaft/axle inspection.
Suspension Steering:
Front and rear suspension component inspection, ball joint and tie rod end servicing, steering linkage alignment, and shock absorber replacement.
Braking System:
Hydraulic brake system diagnostics, brake pad and rotor replacement, brake caliper servicing, and brake fluid bleeding procedures.
Electrical System:
Battery maintenance, charging system (stator, regulator/rectifier) testing, starter motor and solenoid testing, lighting system troubleshooting, and ignition system diagnostics.
Bodywork Chassis:
Frame inspection, plastic body panel removal and installation, seat servicing, and rack inspection.
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, battery testing and charging, tire pressure checks, and general lubrication.
Repair Procedures:
Complete engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnostics and replacement, and bodywork repairs.
Troubleshooting Guides:
Systematic diagnostic flowcharts for common starting, running, electrical, and mechanical problems.
Installation Removal:
Step-by-step instructions for removing and installing major components and sub-assemblies.
Depth Of Coverage:
Comprehensive, covering basic maintenance to full engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Diagnostic Capabilities:
Detailed diagnostic procedures and specifications for electrical components, fuel system, and engine performance.
Rebuild Instructions:
Includes detailed procedures for complete engine and transmission rebuilding, with torque specifications and clearances.
Engine Type:
Likely a 4-stroke, single-cylinder gasoline engine.
Displacement:
Approximately 375cc to 400cc. Specific Polaris designation might be 375 or 400.
Bore X Stroke:
Specifics not in product info but typical for this class, e.g., 83mm x 71.3mm or similar.
Cooling System:
Liquid-cooled (typical for Polaris Sportsman 400 of this era).
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic timing.
Horsepower:
Estimated 25-30 HP. Specific figures require referring to the manual's detailed specifications.
Torque:
Estimated 20-25 ft-lbs. Specific figures require referring to the manual's detailed specifications.
Fuel Delivery:
Carbureted. Specific model (e.g., Mikuni VM series) would be detailed in the manual.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Carburetor Size:
Likely 34mm or 36mm. Specifics in manual.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft drive with Polaris's on-demand AWD (All-Wheel Drive) system, likely with selectable 2WD/4WD.
Optional Transmissions:
None. CVT was standard for this model.
Cvtfuid Type:
Specific Polaris CVT fluid or equivalent. Manual will specify exact type and capacity.
Gear Reduction:
CVT provides infinite gear ratios. Manual will cover any specific reduction gears in the final drive.
Length:
Approx. 83 inches (210.8 cm). Specific dimensions in manual.
Width:
Approx. 46 inches (116.8 cm). Specific dimensions in manual.
Height:
Approx. 48 inches (121.9 cm). Specific dimensions in manual.
Wheelbase:
Approx. 50.5 inches (128.3 cm). Specific dimensions in manual.
Dry Weight:
Approx. 600 lbs (272 kg). Specifics in manual.
Ground Clearance:
Approx. 10.25 inches (26 cm). Specifics in manual.
Rack Capacity Front:
Approx. 100 lbs (45 kg). Specifics in manual.
Rack Capacity Rear:
Approx. 200 lbs (90 kg). Specifics in manual.
Infotainment System:
Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights). No complex infotainment system typical of modern vehicles.
Driver Assistance Features:
On-demand AWD is the primary driver assistance feature for improved traction and control.
Connectivity Options:
No connectivity features such as Bluetooth or USB ports.
Engine Oil Change:
Typically every 50-100 hours or annually. Specific interval in manual.
Air Filter Cleaning:
Recommended every 25-50 hours or as needed based on operating conditions. Specific interval in manual.
Spark Plug Replacement:
Typically every 100-200 hours or annually. Specific interval in manual.
Cvtfuid Change:
Recommended every 100-200 hours or annually. Specific interval in manual.
Engine Oil Type:
SAE 5W-30 or 10W-40, likely a JASO MA certified motorcycle oil. Specifics in manual.
Engine Oil Capacity:
Approx. 1.7 - 2.0 quarts (1.6 - 1.9 liters) with filter change. Specifics in manual.
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Specifics in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Specifics in manual.
Common Wear Items:
CVT belt wear, suspension bushings, ball joints, and wheel bearings are common wear items on ATVs of this age.
Electrical Issues:
Age-related degradation of wiring insulation, stator failure, and regulator/rectifier issues can occur. Manual is crucial for diagnostics.
Engine Performance:
Carburetor clogging or maladjustment, and carbon buildup can affect engine performance. Manual provides proper cleaning and adjustment procedures.
Polarishistory:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles, ATVs, and other powersports vehicles.
Sportsmanlineage:
The Sportsman line is Polaris's flagship ATV series, known for its comfort, utility, and off-road capability. The 400 model typically offered a balance of power and maneuverability.
Production Years:
The Sportsman 400 was produced across various years. The 2002 model represents a specific iteration within this popular line.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States, particularly at their facilities in Minnesota.
