2002 Polaris Sportsman 400/500 HO Service Manual

Technical Scope for the 2002 Polaris Sportsman 400 and 500 H.O.

• Details 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)
• Contains detailed exploded-view diagrams, electrical schematics, and torque specifications for major engine and chassis components
• Instant download access provided directly in your order confirmation
• Fully searchable OCR text layer lets you instantly find specific torque specs or part numbers
• Print exactly what you need for the shop floor without risking a physical book to grease and damage
• Permanent account access—never pay twice if you lose the file
• Serves as the primary technical reference for A02CH42 and A02CH50 chassis builds, providing exact factory-recommended settings for assembly and powertrain maintenance

Inside the Manual

This 354-page factory resource outlines maintenance and service procedures for both ATV models. The material starts with general vehicle identification, including VIN structures and paint codes, before moving into a comprehensive periodic maintenance schedule. Key sections break down the liquid cooling system, PVT transmission, carburetor adjustments, valve clearance, and steering geometry. It also includes thorough disassembly and inspection routines for the top-end, cylinder head, and crankcase. Always verify these factory specifications and adhere to standard shop safety practices before beginning any heavy teardown or maintenance work.

Technical Data and Specifications

The manual provides critical assembly specs and reference values for the EH42PLE05 and EH50PLE13 engine platforms. Key factory limits and capacities include:

• Cylinder head warpage limit: .002 inches
• Intake valve clearance: .006 inches
• Cooling system capacity: 2.25 quarts
• Standard front wheel nut torque: 20 ft.-lbs.
• Detailed jetting and clutch charts for high-altitude adjustment