1996 - 2003 Polaris Sportsman 400 and 500 Service Manual


Because of their reliable design, relatively simple construction, and ease of repair; ATVs are the ideal machine for maintenance and repair at home. With proper care and routine maintenance, your ATVwill provide many years of reliable use. When repairing an ATV, most home mechanics will find them easy to work with and repairs quick and trouble-free.

Scheduled ATV maintenance should occur approximately every 10, 25, 50, 100 and 300 hours. This routine maintenance should include changing the oil, inspecting the shift linkage - steering - suspension - coolant system - fuel system - drive belts - engine mounts, changing the spark plugs, and replacing the fuel and air filters. Having a quality service manual specific to your ATV will help you identify the parts of your ATV and assist you during routine maintenance and repair.

Doing routine maintenance on your ATV at home provides many benefits. It is less expensive than having an ATV shop do the maintenance. It prolongs the life of your ATV. And, it provides you a better understanding of the working components of your ATV.

Even with diligent routine maintenance, ATVs may require periodic repairs. In the event that you need to repair your ATV, it will likely be easier if you have been doing your own routine maintenance as you will be more familiar with the mechanics of your engine. Another asset that makes ATV engine repair easier, is access to service manuals and parts catalogues. Since you already have a maintenance manual that youve been using for routine maintenance, you need only assure that you have on hand a parts catalogue for any repairs that are necessary.

Your ATV will provide you with many years of service. Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.

497 pages in english pdf format that enables you to print only what you need.

Contents include

Periodic maintenance, component inspection, lubricants, fuel system and air intake, engine, transmission, cooling system, final drive, electrical and ignition system including wiring diagrams, suspension, brake system.
Includes information unique to 2001 and on models including the sportsman 400.