2002 Polaris Sportsman 400/500 HO Service Manual
Complete 2002 Polaris Sportsman 400 and 500 HO ATV service manual covering maintenance, troubleshooting, and repair of major systems. Includes diagrams and specifications.
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Models Covered & Key Technical Specifications
Polaris Sportsman 400 and Sportsman 500 HO (2002) Polaris Sportsman 400 and Sportsman 500 HO Comprehensive Service & Repair Manual (2002) Parts-Reference | Automotive Directory Compendium. | Series ATV. Published Tightening Data: 5 to 6.5 ft.-lbs. (7-9 Nm) is measured at the Camshaft Sprocket. Specific Fill Levels: The Fuel Tank capacity maintains 3.2 Gallons (12.1 L). Integral Tolerance Values: The Front Suspension travel is 6.7 inches (17.02 cm). Operational Amperage Specs: The Alternator Output delivers 200 Watts. Established Feed Speed: The Top Speed Capability represents 64 MPH (103 KPH). Authorized Bolt Torques: The Wheel Base limits 50.50 inches (128.27 cm) Standards.
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Polaris Sportsman 400 and Sportsman 500 HO Service Manual: Polaris Sportsman 400 and Sportsman 500 HO Comprehensive Service & Repair Manual (2002) Parts-Reference
Specification-Class: Sportsman 400, Sportsman 500 H.O. // Model-Portfolio: 2002 // Specification-Class: ATV
| TOP | Performance-Element | Rating | Calibration-Data |
|---|---|---|---|
| Maximum Power Output | 27 HP @ 6000 RPM | Standard Engine Speed Capability | |
| Top Speed Capability | 64 MPH (103 KPH) | Estimated Maximum Operational Velocity | |
| Fuel Capacity | 3.2 Gallons | Standard Fuel Tank Volume Capacity | |
| Dry Weight | 597 lbs. (271 kg) | Approximate Operational Vehicle Mass | |
| Towing Capacity | 850 lbs. (385.6 kg) | Maximum Permissible Load Weight Capacity | |
| Engine Displacement | 425cc (499cc) | Standard Engine Cylinder Volume Capacity |
Providing a structural breakdown of all systems and procedures for the Polaris Sportsman 400 and 500 HO.
Engine Service Data
The engine service data chapter documents critical specifications for the EH42PLE and EH50PLE engines. It details component dimensions, tolerances, and performance parameters for optimal engine health and longevity.
Drive Clutch Operation
This section details the fundamental workings of the drive clutch, explaining how shift weights and the coil spring interact to control engagement RPM and initiate upshifting based on engine speed.
PVT System Sealing
This documentation outlines the importance of PVT system sealing for air cooling efficiency and preventing contamination. It highlights the role of intake ducts and vented covers, especially under wet conditions.
Carburetor Assembly Procedures
Instructions for correctly assembling the carburetor, including specific guidance on the placement of spring seats, spacer washers, and diaphragm positioning for accurate fuel mixture delivery.
Frame, Nuts, Bolts, Fasteners
Guidance on periodically inspecting the tightness of all fasteners to ensure vehicle integrity and safe operation. It also stresses the importance of checking cotter pin placement.
This manual thoroughly documents the repair and maintenance procedures for your Polaris Sportsman 400 and 500 HO ATVs. It includes detailed steps for engine, fuel system, and PVT system servicing, ensuring peak performance.
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