Polaris Sportsman 400/500 HO ATV 2002 Service Manual (P/N 6515 3400 13)

• Exact model coverage: This 354-page PDF covers the 2002 Polaris Sportsman 400, model numbers A02CH42AA/AB/AC/AD/AE/AF, and the Sportsman 500 H.O., DUSE H.O., and RSE H.O., model numbers A02CH50AA/AB/AC/AD/AE/AF/AG/AH. Polaris identifies the service manual as Item No. 9917202.
• Engine repair depth: Covers EH42PLE05 and EH50PLE13 engine removal and installation, top- and bottom-end disassembly, cylinder-head and valve-seat work, piston and cylinder inspection, crankcase and bearing service, oil-pump work, cam timing, final assembly, and EH50PL water-pump mechanical-seal replacement with the engine installed.
• The fuel and PVT sections document Mikuni BST 34 and BST 40 carburetor overhaul and adjustment, altitude/temperature jetting selection, fuel-pump service, standard and EBS clutch diagnosis, drive and driven clutch rebuilding, bushing service, belt inspection, alignment, offset, and overheating troubleshooting.
• Transmission, AWD, steering, and brake procedures include transmission removal and internal repair, output-housing end play and backlash adjustment, Hilliard clutch and magnetic-coil service, front and rear drive-shaft work, CV boots, hubs, A-arms, struts, ball joints, hydraulic brake bleeding, and caliper repair.
• Electrical coverage provides test charts and fault isolation for the electronic speedometer, AWD engagement, reverse-speed limiting, wheel-speed sensor, gear-position switches, ETC switch, cooling-fan circuit, ignition, charging, battery, and starter systems, plus separate 2002 Sportsman 400 and 500 wiring diagrams.
• Factory reference material includes exploded views, oil-flow and fuel-flow diagrams, torque tables, fluid specifications, inspection limits, clearances, clutch and jetting charts, electrical test values, and Polaris special-tool numbers.
• Permanent account access keeps the purchased PDF available for future re-downloads.

Inside the Manual

This is shop-level service information, not an owner’s handbook with a few maintenance pages. Its teardown depth, measuring procedures, and reliance on model-specific service tools make it best suited to professional technicians and experienced ATV owners who are already comfortable with engine, drivetrain, brake, and electrical repair.

The opening chapters identify the VIN, engine, transmission, and machine-number locations, then separate the 400 and 500 H.O. specifications, paint codes, lubrication requirements, and periodic maintenance. Routine work includes shift-linkage and carburetor adjustment, compression and cooling-system pressure tests, oil-pump priming, valve-clearance service, toe alignment, front-hub maintenance, auxiliary-brake testing, and wheel and tire inspection.

Model-Specific Systems and Diagnostics

The Sportsman 400 uses the EH42PLE05 engine, BST 34 carburetor, standard non-EBS PVT arrangement, and 200-watt alternator; the 500 H.O. uses the EH50PLE13, BST 40, Engine Braking System clutch package, and 250-watt alternator. Those differences carry through the carburetor views, jetting data, clutch charts, flywheel identification, and electrical testing. Belt-tension adjustment is specifically a non-EBS procedure, while the EBS section adds one-way clutch inspection and dedicated drive and driven clutch bushing repair.

Diagnostic depth goes beyond symptom lists. The manual provides electronic-speedometer flowcharts for loss of AWD, display and odometer faults, reverse-limiter problems, AWD hub safety limiting, and wheel-speed-sensor checks. Named visual references include the EH42PL/EH50PL oil-flow diagram, BST 34 and BST 40 carburetor exploded views, EBS clutch exploded view, AWD front-housing exploded view, transmission exploded view, and model-specific wiring schematics.

Technical Data, Tooling, and Repair Cautions

Component chapters pair the repair procedures with factory torque sequences, capacities and approved lubricants, wear limits, end-play and backlash data, valve and piston clearances, and brake specifications. Clutch spring and shift-weight charts, altitude-based jetting tables, and voltage, resistance, and current tests are also included.

Significant tools are identified by number, including Water Pump Mechanical Seal Puller 2872105, Crankshaft/Water Pump Seal Install Kit 2871283, EBS Clutch Alignment Tool 2872292, Hilliard Clutch Garter Spring Installation Tool 2870888, and Transmission Backlash Setting Tool 2871695.

The engine chapter warns that confusing the flywheel advance marks with the single TDC timing mark can leave the cam incorrectly timed and cause serious engine damage. It also cautions that side-loading or striking the installed-engine water-pump seal puller can bend the pump shaft, turning a seal repair into engine removal and crankcase separation.

This PDF is the service manual only; the factory publication table points to separate model-specific owner’s and parts manuals. Follow the manual’s warnings for pressurized cooling-system work, fuel handling, hydraulic brakes, batteries, and rotating PVT components before inspection or disassembly.