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3,301,516 satisfied buyers
2001 Polaris Sportsman 400 500 ATV Service Repair Manual
Description:
Get the complete workshop PDF download for your 2001 Polaris Sportsman 400 / 500 ATV! This professional service manual covers all 1996-2003 models, including the 1997-2001 Polaris Worker 500 and 1997 Polaris Xplorer 500. Perfect for DIY mechanics and technicians, it provides comprehensive repair, maintenance, and troubleshooting guidance with detailed 400 500 specs and diagrams for every component.
Covered Models & Years:
- 2001-2003 Polaris Sportsman 400 (All configurations)
- 1996-2003 Polaris Sportsman 500 (All variants)
- 1997-2001 Polaris Worker 500
- 1997 Polaris Xplorer 500
Manual Covers:
1. General Information - Safety protocols & tool requirements
2. Maintenance - Scheduled service intervals
3. Engine - Top-end rebuilds & bottom-end service
4. Electronic Fuel Injection - Diagnostics & calibration
5. Body / Steering / Suspension - Frame & control repairs
6. Clutching - Primary/secondary clutch adjustment
7. Final Drive - AWD system diagnostics
8. Transmission - Gearcase disassembly
9. Brakes - Hydraulic disc service
10. Electrical - Stator/CDI testing
11. Wiring Diagrams - Color-coded schematics
Key Features:
- 400 500 parts manual references with OEM numbers
- Troubleshooting flowcharts for common issues:
Hard starting in cold weather
AWD engagement failures
Electrical shorts
- Torque specifications for critical fasteners
- EFI diagnostics for 2001+ models
- Carburetor jetting charts for pre-2001 models
Technical Specifications:
- File Format: PDF | 39.6 MB
- Compatibility: Windows & Mac (All Versions)
- Language: English
- Requirements: Adobe PDF Reader & WinZip
Why This Manual Wins:
This Polaris ATV 1996-2003 Sportsman 400 500 workshop PDF download includes:
Factory-accurate diagrams for every repair
Year-specific adjustments (1996 vs 2001 models)
Transmission shimming procedures
EFI error code interpretation
Wiring harness repair guides
Long-Tail Keyword Solutions:
- 2001 Sportsman 500 EFI reset procedure
- 1997 Xplorer 500 clutch replacement
- Sportsman 400 carburetor rebuild
- Worker 500 brake bleeding steps
File Data
This file is sold by repairguid, an independent seller on Tradebit.