2001 Polaris Sportsman 400, 500 DUSE & 500 H.O. ATV Service Manual (P/N 9916581)

Polaris service manual P/N 9916581 for the 2001 Sportsman 400 and Sportsman 500 DUSE, including the 500 H.O., H.O. DUSE, and H.O. RSE variants. It covers the EH42PLE05, EH50PLE09, and EH50PLE13 engine installations and Gen IV chassis.

• Engine repair: Engine removal, cylinder-head service, valve-seat reconditioning, piston and ring inspection, crankcase disassembly, and camshaft timing.

• Carburetion: Mikuni BST 34 and BST 40 disassembly, inspection, float adjustment, needle-and-seat leakage testing, and fuel-pump service.

• Cooling system: Pressure testing, thermostat specifications, coolant-flow diagrams, water-pump mechanical-seal replacement, and cooling-system bleeding.

• PVT and transmission: Standard and EBS clutch service, bushing replacement, belt alignment, and High/Low/Reverse gearbox disassembly and reassembly.

• Final drive: AWD Hilliard clutch inspection, magnetic-coil service, front gearcase overhaul, wheel-bearing work, and CV joint boot replacement.

• Chassis and brakes: MacPherson strut and ball-joint replacement, steering alignment, master-cylinder rebuilding, caliper service, and hydraulic bleeding.

• Electrical diagnosis: Ignition and charging tests, starter-motor rebuilding, electronic speedometer troubleshooting, gear-position switch tests, and wiring diagrams.

The internal repair and diagnostic sections suit experienced technicians with measuring equipment; Polaris expressly reserves PVT repair for factory-trained, authorized technicians using the specified special tools.

Engine Service and Cooling

Engine inspection data cover cylinder-head measurements, crankshaft runout, valve-stem diameters, and camshaft journal clearances. Piston and ring identification, cam-chain tensioner inspection, and automatic compression-release service are documented alongside assembly illustrations and component-specific torque specifications.

The EH42PL / EH50PL Oil Flow Diagram follows the dry-sump lubrication circuit. The lubrication sections identify Polaris Premium 4 Synthetic 0W/40 engine oil and explain oil-pressure testing and pump priming.

For EH50PL engines, the water-pump mechanical-seal procedure uses puller P/N 2872105 with the engine installed, allowing seal replacement without splitting the crankcases. The manual warns that side-loading the puller can bend the pump shaft, turning the job into an engine-removal and crankcase-separation repair.

Mikuni Carburetors and Fuel Delivery

The Sportsman 400 and 500 DUSE use the BST 34; the 500 H.O. variants use the BST 40. Separate exploded views and adjustment data distinguish these carburetors.

The Fuel Flow Diagram traces the tank, valve, filter, pump, and carburetor connections. Jetting charts account for altitude and temperature, while the service sections cover vacuum-slide and diaphragm inspection, pilot-mixture adjustment, and pressure-regulated fuel-pump disassembly and testing.

PVT, Gearbox and AWD Service

Standard PVT belt-deflection adjustment is separate from EBS service. EBS belt deflection is not adjustable, and its driven clutch does not use the standard helix-position adjustment. Clutch spring and shift-weight charts, together with the EBS Exploded View, support the model-specific service information.

The transmission chapter goes beyond linkage adjustment. It covers the selector box, internal gears and chains, front output “snorkel” housing, shaft end play, and output-gear backlash.

AWD coverage combines magnetic-coil testing with Hilliard clutch, armature-plate, and pole-gap inspection. The hub section warns that outward hub movement after installation can disengage the armature-plate tabs and damage the roller clutch. Front and rear driveshaft sections distinguish CV joint cleaning from boot replacement and specify the associated grease requirements, including Demand Drive Hub Fluid for the front hubs.

Chassis and Hydraulic Brakes

Chassis procedures include strut-cartridge replacement, A-arm service, ball-joint replacement, and steering toe alignment. Torque references cover engine fasteners, wheel nuts, and suspension hardware.

The Cutaway View of DH Caliper explains the independent hand-brake and auxiliary foot-brake circuits and their separate bleeding requirements. Brake inspection covers pad wear, disc thickness and runout, caliper condition, and master-cylinder components.

Working on high-pressure hydraulic brakes and volatile fuel systems carries inherent risks. Follow the manual’s system-specific safety precautions.

Electrical Fault Finding

Ignition and charging flowcharts accompany starter voltage-drop tests and starter-motor brush and armature inspection. Electronic speedometer troubleshooting also addresses wheel-speed sensing, reverse limiting, and AWD engagement control.

The Electronic Speedometer Wiring Diagram supplements connector-pin information. Separate main wiring diagrams cover the Sportsman 400 and early- and late-production Sportsman 500 configurations.

A Preview of Valve and Carburetor Settings

These examples represent a small selection of the manual’s adjustment data.

For the covered engines, intake and exhaust valve clearance is 0.006 in. (0.15 mm), checked cold at TDC on the compression stroke.

Carburetor float height is 13.0 ± 1 mm for the BST 34 and 14.7 ± 1 mm for the BST 40. The measurement is taken from the float-bowl mating surface to the float step without compressing the inlet-needle spring.

Searchable Text, Chapter Bookmarks and Wiring Sheets

Search, navigation, and diagram detail: Main text is searchable, while image-based diagram lettering—including the speedometer schematic and three main wiring sheets—is not. Embedded bookmarks open all ten chapters, the index, and the main wiring sheets. Small wiring labels require zooming; the speedometer schematic is noticeably lighter than the three main sheets.

One printable English PDF contains 381 pages total. That total already includes the opening chapter-index page, one notes page, the six-page alphabetical index, and all three main wiring-diagram sheets.