1996 – 2004 Polaris Sportsman 400 500 Carbureted 4-Stroke ATV Service Manual Cyclepedia


In stock

SKU: CPP-249 Category: Tag:


Do you need to service your 1996 – 2004 Polaris Sportsman 400 500 Carbureted 4-Stroke ATV.   The Cyclepedia, printed and bound 1996 – 2004 Polaris 400 500 Carbureted 4-Stroke 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 4-stroke ATV Model 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

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

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

External Components
Exhaust System
Front Fender
Meter Housing
Rear Fender

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

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

Cooling System
Water Pump

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

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

Front Suspension
Front Struts

Rear Suspension

Steering Shaft
Tie Rods

Wheels and Hubs

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

The 1996-2004 Polaris Sportsman 400 and 500 Carbureted 4-Stroke ATVs are renowned for their durability, power, and versatility, making them popular choices among off-road enthusiasts and utility riders.

Key features and aspects of these models include:

Engine Performance: They were equipped with reliable, carbureted, 4-stroke engines. The Sportsman 400 featured a 425cc engine, while the Sportsman 500 had a larger 499cc engine. These engines provided a good balance of power and efficiency for various terrains and tasks.

4×4 Capability: These Sportsman models were known for their excellent 4×4 capabilities, featuring Polaris’ All-Wheel-Drive (AWD) system that provided traction and stability in challenging off-road conditions.

Versatility: They were designed to handle both recreational riding and utility tasks. With ample towing capacity and cargo racks, these ATVs were suitable for hauling and carrying loads, making them popular on farms, ranches, and outdoor work environments.

Comfort and Handling: They offered decent ergonomics and rider comfort, with features such as comfortable seating, effective suspension systems, and responsive handling for various terrains.

Reliability: Known for their reliability and durability, these models earned a reputation for being robust and capable of enduring rough riding conditions.

Carbureted Design: Being carbureted, they relied on a traditional fuel delivery system. While this design is straightforward, it might require occasional maintenance and adjustments to ensure optimal performance, especially in varying weather conditions.

Model Variants: Throughout the years of production, there were different variants and improvements made to these models, with changes in features, designs, and minor upgrades in performance.

These Sportsman models played a significant role in establishing Polaris as a key player in the ATV market. Their reliability, versatility, and capability made them popular among riders who sought a balance between recreational riding and practical utility use.

Additional information

Weight 4.1 lbs
Dimensions 13 × 12 × 1.75 in

No further products found.