Note: While we do our best to provide accurate up to date photos, book covers and packaging vary with date of manufacture. This is NOT a collectible repair manual, it is the current printing. Seller not responsible for the manufacturer's print quality.
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
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
If you need to speak with us please call 1-800-426-4214 (Monday - Friday / 9am - 2pm EST).
ABOUT US - Since 1997 we've been helping vehicle owners find the repair information they need. We specialize in repair manuals, owners manuals and parts manuals. We can help you find the right manual for your motorcycle, ATV, tractor, car or boat. Give us the opportunity to serve you. Learn more about us...
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Motocom, Inc., d/b/a RepairManual offers access to a diverse repair manual library. In-as-much as our roots are grounded in motorcycles and motorcycling, we offer repair manuals relating to cars, trucks, vans, all terrain vehicles, snowmobiles, tractors, and personal watercraft.
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