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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Sample pages from the 2002 Polaris Sportsman 400/500 HO Service Manual manual
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Polaris Models Covered & Key Technical Specifications
Models: Polaris Sportsman 400, Polaris Sportsman 500 H.O.
Sub-models / Variants: 400 (A02CH42AA/AB/AC/AD/AE/AF), 500 H.O. (A02CH50AA/AB/AC/AD/AE/AF/AG/AH), DUSE H.O., RSE H.O.
Build Years: 2002
Technical Data:
- Engine Displacement: 425 cc (Sportsman 400), 499 cc (Sportsman 500 H.O.)
- Engine Configuration: 4-Cycle, Single Cylinder, Liquid Cooled
- Transmission Type: PVT (Polaris Variable Transmission)
- Fuel System: Mikuni BST 34 (400), Mikuni BST 40 (500 H.O.)
- Fuel Tank Capacity: 5.25 gallons (19.9 liters)
- Drive System: Shaft Drive with 2/1 Front Drive Ratio
- Electrical Output: 200 Watts (400), 250 Watts (500 H.O.)
- Front Suspension: MacPherson Strut with 6.7 inches of travel
- Rear Suspension: Progressive Rate Independent with 9.5 inches of travel
- Braking: Single Lever Hydraulic Disc (Hand), Hydraulic (Auxiliary Foot)
Polaris Manual Features & Content Preview
Technical Scope for the 2002 Polaris Sportsman 400 and 500 H.O.
- Covers 2002 Polaris Sportsman 400 and 500 H.O. ATV models, including DUSE and RSE high-output variants
- Original OEM publication P/N 9916632, first edition, 2002 release
- Contains detailed exploded-view diagrams, electrical schematic references, and torque specifications for major engine and chassis components
- File link appears in your order confirmation straight away
- OCR text layer lets you jump to a torque spec by keyword
- Suitable for printing individual sections for shop-floor use
- Permanent availability in your purchase account — no re-buy required
- This official publication serves as the primary technical reference for the A02CH42 and A02CH50 chassis builds, providing exact factory-recommended settings for engine assembly and powertrain maintenance
Engine and Maintenance Walkthrough
This 354-page factory manual documents maintenance and service procedures for the 2002 Polaris Sportsman 400 and 2002 Polaris Sportsman 500 H.O. The content begins with general vehicle identification, including VIN structures and paint codes, followed by a comprehensive periodic maintenance section. Key chapters document service steps for the liquid cooling system, PVT transmission, carburetor adjustment, valve clearance procedures, and steering system geometry. The manual also provides detailed disassembly and inspection routines for the top-end, cylinder head, and crankcase components.
Technical Data and Specification Highlights
Technical data provided includes critical assembly specs and reference values for the EH42PLE05 and EH50PLE13 engine platforms. Cylinder head warpage limit is set at.002 inches. Intake valve clearance is specified at.006 inches. The cooling system capacity is documented at 2.25 quarts. Standard torque for front wheel nuts is 20 ft.-lbs. Detailed jetting charts and clutch charts are included for high-altitude adjustment. An official 354-page Polaris OEM service manual covering the 2002 Polaris Sportsman 400 and 500 H.O., documenting engine, chassis, electrical, and cooling system specifications for the A02CH-series factory build.
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