The Polaris Sportsman is a versatile and capable All-Terrain Vehicle (ATV) renowned for its utility and performance in various terrains. Introduced in 2002, this model falls within the second generation of the esteemed Sportsman line, offering a blend of power, comfort, and advanced features for its era. Key attributes include a True All-Wheel Drive system, independent rear suspension, and robust engine options, such as the 400cc and 499cc variants, designed for work, recreation, and demanding trail riding. The Sportsman line has consistently been recognized for its balance of power and maneuverability, positioning it as a strong contender against competitors like Yamaha, Honda, Kawasaki, and Suzuki in the early 2000s.
This comprehensive manual serves as an essential resource for owners and technicians alike, detailing the maintenance, repair, and technical specifications for the 2002 Polaris Sportsman 400 4x4, 500 DUSE 4x4, 500 HO 4x4, and 500 RSE 4x4 models. It covers critical systems including the engine, drivetrain, suspension, steering, fuel, and electrical systems, providing step-by-step procedures for routine maintenance, component installation, and advanced troubleshooting. With detailed guidance on everything from oil changes and filter replacements to engine rebuilds and electrical diagnostics, this manual ensures the optimal performance and longevity of your Polaris Sportsman ATV.
Vehicle Type:
All-Terrain Vehicle (ATV)
Vin Decoder Reference:
Not applicable for manual description, but VIN is typically 17 characters for ATVs.
Atv Generation:
This manual covers the 2002 model year, which falls within the second generation of the Polaris Sportsman line.
Atv Market Segment:
The Polaris Sportsman series is positioned as a versatile and capable all-around utility ATV, suitable for work, recreation, and trail riding. The 400 and 500 models offer a balance of power and maneuverability.
Competitors 2002:
Competitors in 2002 included models from Yamaha (Kodiak, Grizzly), Honda (FourTrax Foreman, Rancher), Kawasaki (Bayou, Prairie), and Suzuki (King Quad).
Polaris Sportsman Features 2002:
Features often included Polaris's True All-Wheel Drive (AWD) system, independent rear suspension (IRS), powerful engine options (400cc, 500cc), comfortable seating, and rugged chassis for various terrains.
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
Estimated Page Count:
Typically 300-500 pages for a comprehensive ATV service manual of this era. Actual count not provided, but described as comprehensive.
Manual Type:
Downloadable PDF Repair, Service, and Shop Manual. Also mentioned are Owner's Manuals and Parts Catalogs as available from the seller.
File Format:
PDF (Plain, simple, easy to use, no zip files)
Engine Systems:
Engine removal and installation, lubrication and cooling system, engine specifications, intake & exhaust.
Drivetrain Systems:
Transmission, drive chain & sprockets, 4x4 system operation and maintenance.
Suspension Steering:
Shocks, steering system.
Fuel Ignition Electrical:
Fuel system, electrical system.
General Maintenance:
Routine maintenance, general information.
Troubleshooting:
Advanced troubleshooting.
Maintenance Procedures:
Oil changes, filter replacements, chain adjustments, lubrication, fluid checks and changes, spark plug replacement, air filter servicing, coolant checks and flushes.
Repair Procedures:
Engine rebuilds, transmission overhaul, carburetor cleaning and adjustment, brake system service, shock absorber replacement, electrical component diagnosis and repair, steering linkage repair.
Diagnostic Procedures:
Troubleshooting guides for common starting, running, electrical, and mechanical issues. Specific diagnostic steps for various systems.
Component Installation:
Detailed procedures for engine removal/installation, transmission removal/installation, and other major component replacements.
Depth Of Coverage:
Comprehensive coverage from basic maintenance to advanced engine and transmission diagnostics and repairs. Suitable for DIY mechanics and professional technicians.
File Quality:
Described as plain, simple, easy to use PDF. Assumed to be high resolution and searchable text for efficient navigation and printing.
Printability:
Designed to be printable for on-site use without damaging original paper manuals.
Binding:
Not applicable (digital download)
Paper Quality:
Not applicable (digital download)
Engine Type 400:
4-stroke, SOHC, single-cylinder. Likely a Polaris liquid-cooled engine, approximately 375cc-400cc displacement.
Engine Type 500:
4-stroke, SOHC, single-cylinder. Polaris liquid-cooled engine, 499cc displacement.
Engine Variants:
400 4x4, 500 HO (High Output), 500 DUSE (Durable Utility Sports Edition), 500 RSE (Rough Stock Edition).
Horsepower 500 Ho:
Approximately 30-33 HP (specific figures vary by source and tuning).
Torque 500 Ho:
Approximately 28-30 ft-lbs (specific figures vary by source).
Carburetor Type 400:
Likely a Mikuni or Keihin carburetor, possibly a 34mm or 36mm unit.
Carburetor Type 500:
Likely a Mikuni BSR42 or similar 42mm flat-slide carburetor for the HO models.
Fuel Type:
Unleaded gasoline, 87 octane recommended.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse.
Optional Transmission:
Not applicable, CVT was standard across these models.
Cvta Benefits:
Provides seamless gear changes and keeps the engine in its optimal power band for varying terrain and load conditions.
Drive System:
Shaft drive to rear wheels, with automatic engagement 4WD (AWD) system, typically activated by front driveshaft.
Overall Length:
Approximately 81-83 inches (2057-2108 mm) depending on specific model variant.
Overall Width:
Approximately 46 inches (1168 mm).
Overall Height:
Approximately 48-50 inches (1219-1270 mm).
Dry Weight 500:
Approximately 573 lbs (260 kg).
Ground Clearance:
Typically around 10.5 inches (267 mm).
Towing Capacity:
Typically rated for 1,500 lbs (680 kg).
Rack Capacity Front:
Typically rated for 90 lbs (41 kg).
Rack Capacity Rear:
Typically rated for 150 lbs (68 kg).
Atv Safety Standards:
As per industry standards for ATVs, emphasizes responsible riding and adherence to safety guidelines. No formal crash test ratings like cars.
Braking System:
Hydraulic disc brakes on all wheels, often with front and rear master cylinders. Parking brake typically on rear caliper.
Aawd System:
Polaris's True All-Wheel Drive (AWD) engages front wheels automatically when rear wheels lose traction, enhancing control.
Lighting:
Dual headlights and a taillight/stoplight for visibility.
Chassis Design:
Robust steel frame and suspension components designed for durability and stability.
Infotainment Systems:
Basic instrumentation includes speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems typical of modern vehicles.
Driver Assistance Features:
The primary technological feature is the automatic AWD system. No electronic driver assistance aids like traction control or ABS.
Connectivity Features:
No onboard connectivity or Bluetooth features. Designed for functional utility and off-road performance.
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Check manual for specific oil type and capacity.
Air Filter Service:
Inspect every 20 hours, clean or replace as needed. More frequent service in dusty conditions.
Spark Plug Replacement:
Recommended every 100-200 hours or annually. Check gap specifications.
Cv Belt Inspection:
Inspect every 50-100 hours for wear, cracks, or fraying. Replace if any damage is noted.
Engine Oil Type:
Polaris PS-4 5W-50 Synthetic is commonly recommended for these models. Consult manual for exact specifications and capacities.
Coolant Type:
Permanent type antifreeze/coolant, typically a 50/50 mix of ethylene glycol and distilled water. Check manual for specific recommendations.
Gearcase Oil:
Polaris Hypoid 75W-90 Gearcase Lubricant or equivalent.
Common Wear Items:
CVT belt wear, suspension bushings, tie rod ends, wheel bearings, and brake pads are common wear items on ATVs of this age and usage.
Carburetor Issues:
Carburetors can become clogged with debris or stale fuel, leading to starting issues, rough idling, or poor performance. Regular cleaning and proper fuel storage are crucial.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent faults. Checking and cleaning connectors is good practice.
Polaris History:
Polaris Inc. is a long-standing American manufacturer of powersports vehicles, known for its pioneering work in snowmobiles and later expanding into ATVs, UTVs, and motorcycles.
Sportsman Line Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving significantly over the years with advancements in engine technology, suspension, and rider comfort. The 2002 models represented a mature iteration of the Sportsman platform.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
Model Awards:
Specific awards for the 2002 Sportsman models are not readily documented, but the Sportsman line consistently received praise for its utility, comfort, and off-road capability during its production years.
