1996 – 2004 Polaris 400 500 Sportsman ATV Online Service Manual

The Cyclepedia Polaris Sportsman 400 and 500 Online Service Manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran ATV technician. PLUS you get tech support with a real live person, should you need it.

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

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

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

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

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

Cooling System
Coolant
Radiator
Thermostat
Water Pump

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

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
A-arms
Front Struts

Rear Suspension
Installation
Removal

Steering
Handlebar
Steering Shaft
Tie Rods

Wheels
Wheels and Hubs

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