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1996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_1
1996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_21996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_31996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_41996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_51996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_61996 - 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia_Page_7

1996 – 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual Cyclepedia

$49.90 $32.95

In stock

SKU: CPP-249-P Category:

Product Description

The Cyclepedia, printed and bound 1996 – 2004 Polaris 400 500 Carburated Sportsman ATV Service Manual includes everything you need to fully service and rebuild your Polaris Sportsman ATV. Includes hundreds of detailed step by step instructions, black and white photos and specifications.

Purchase this printed manual and get 1 year of FREE access to the online version (full color) plus technical support. If you are a do it yourselfer this is the best manual you can buy for your Polaris ATV!

Polaris ATV Coverage

1996 Sportsman 500
1997 Sportsman 500
1998 Sportsman 500
1999 Sportsman 500
2000 Sportsman 500
2001 Sportsman 400
2001 Sportsman 500
2002 Sportsman 400
2002 Sportsman 500
2003 Sportsman 400
2003 Sportsman 500
2004 early Sportsman 400
2004 early Sportsman 500

Table of Contents

 Polaris Sportsman 400 500 Engine Compression Test Specification Service Specifications and Torque Specs

Service Information
Quick Reference
Special Tools
Specifications
Torque Specifications
VIN and Engine Number Location

Polaris Sportsman 400 500 Oil and Filter Change Periodic Maintenance Schedule Chart

Periodic Maintenance
Periodic Maintenance Chart
Brake Fluid
Air Filter Servicing
Brake Inspection
Compression Test
Engine Idle Speed
Lubrication
Engine Oil
Front Gearcase Oil
Hub Fluid
Fuel Hose Inspection
Spark Arrestor
Spark Plug
Throttle Free Play
Tires
Steering Inspection
Transmission Linkage Inspection
Transmission Oil
Valve Adjustment

 Polaris Sportsman 400 500 side cover removal and installation

External Components
Bumpers
Exhaust System
Footrests
Front Fender
Meter Housing
Rear Fender
Seat

Fuel System
34mm Carburetor Assembly
34mm Carburetor Disassembly
40mm Carburetor Assembly
40mm Carburetor Disassembly
Airbox
Carburetor Installation
Carburetor Removal
Fuel Pump
Fuel Tank
Fuel Valve
Throttle

Polaris Sportsman 400 500 recoil starter engine troubleshooting service and repair

Engine
Rocker Arms
Camshaft
Cylinder Head
Valves
Cylinder and Piston
Recoil Starter
Stator Side Engine Components
Crankcase
Crankcase Bearings
Oil Pump
Crankshaft
Engine Installation
Engine Removal

Polaris Sportsman 500 radiator coolant drain valve

Cooling System
Coolant
Radiator
Thermostat
Water Pump

 Polaris Sportsman 400 500 PVT clutch rebuild service compressor tool

Transmission
Gearshift
PVT Belt
PVT Case
PVT Drive Clutch
PVT Driven Clutch
PVT Inspection
PVT Installation
PVT Removal
Snorkel Shaft
Transmission Assembly
Transmission Disassembly
Transmission Removal
Transmission Shafts

Final Drive
CV Boot
Front Drive Axles
Front Gearcase
Front Gearcase Type I
Front Gearcase Type II
Front Hubs
Hub Coils
Prop Shaft
Rear Drive Axles
U-joints

Polaris Sportsman 400 500 brake caliper seal replacement rebuild service

Brake System
Aux Master Cylinder
Brake Discs
Brake Pedal
Front Brake Calipers
Front Master Cylinder 1996-2000
Front Master Cylinder 2001-2004
Rear Brake Caliper
Transmission Shaft Brake Caliper

Polaris Sportsman 400 500 front strut ball joint replacement

Front Suspension
A-arms
Front Struts

Polaris Sportsman 500 rear A-arm bushing replacement

Rear Suspension
Installation
Removal

Polaris Sportsman 400 500 steering tie-rod separation

Steering
Handlebar
Steering Shaft
Tie Rods

Polaris Sportsman 400 500 front wheel hub removal lug nut torque spec

Wheels
Wheels and Hubs

Polaris Sportsman 400 500 gear position switch inspection electrical troubleshooting wiring diagram

Electrical Systems
Battery
Charging System
Diagnostic Mode
Electric Start System
Ignition System
Lights
Meter 1996-2002
Meter 2003-2004
Power Box
Speed Limiter System
Starter Motor
Switches
Wiring Diagrams

Additional Information

Weight 3.32 lbs
Dimensions 13 x 11 x 1.75 in