🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400/500

Year:

2001

Vehicle Type:

All-Terrain Vehicle (ATV)

Engine Variants:

400cc, 500cc

Manual Product Code:

Not specified in product information

👋 Introduction

Positioning:

Essential tool for Polaris Sportsman 400/500 owners seeking to perform maintenance and repairs, catering to DIY enthusiasts and independent shops.

Value Proposition:

Provides comprehensive and detailed repair information at a lower cost than dealership service, empowering owners to save money and maintain their ATVs effectively.

Features:

Instant download, step-by-step instructions, detailed diagrams, parts lists, and troubleshooting guides for a wide range of repair scenarios.

📋 Manual Details

General Maintenance:

Included

Engine:

Included

Fuel System Carburetion:

Included

Body Suspension:

Included

Pvt System:

Included

Final Drive:

Included

Transmission:

Included

Brakes:

Included

Electrical System:

Included

Estimated Page Count:

Not specified, but described as 'comprehensive'

Type:

Service Repair Manual

Language:

English

Downloadable:

YES

File Format:

PDF

Compatibility:

All Versions of Windows & Mac

Printability:

All pages are printable

Software Requirement:

Adobe PDF Reader

📖 Manual Coverage

Engine Systems:

Internal engine components, top-end, bottom-end, cooling, lubrication, ignition, and timing.

Fuel And Emission Systems:

Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, and emissions control components.

Drivetrain Systems:

Primary drive clutch (PVT), secondary clutch, drive belts, final drive housing, axle, and universal joints.

Suspension And Steering:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering linkage, and tie rods.

Brake Systems:

Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, and brake rotors.

Electrical Systems:

Wiring diagrams, battery, starter motor, charging system (stator, regulator/rectifier), lighting, ignition system, and electrical component troubleshooting.

Body And Frame:

Body panels, fenders, racks, seat, handlebars, and frame inspection.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning, and lubrication points.

Troubleshooting:

Diagnostic procedures for common problems, symptom identification, and step-by-step fault finding.

Repair And Rebuild:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and adjustment.

Technical Data And Specifications:

Torque specifications, fluid capacities, clearances, electrical values, and diagnostic data.

Depth:

Comprehensive, covering all aspects from basic maintenance to full engine and transmission rebuilds. Includes detailed diagrams and parts lists.

📊 Manual Specifications

Format:

PDF

Searchability:

Implied by PDF format, likely searchable text if properly created.

Quality:

High-quality, printable pages.

Type:

Digital Download (PDF)

Type:

Not applicable (digital format)

⚙️ Engine Specifications

Engine Type 400:

4-stroke, liquid-cooled, SOHC, 2-valve, single-cylinder (Likely a derivative of the Polaris Pro-Star engine family)

Engine Type 500:

4-stroke, liquid-cooled, SOHC, 2-valve, single-cylinder (Likely a derivative of the Polaris Pro-Star engine family)

Displacement 400:

Approximately 375-400cc (Specific designation may vary)

Displacement 500:

Approximately 499-500cc (Specific designation may vary)

Bore X Stroke 500:

Typical for 500cc Pro-Star: Approx. 94mm x 71.5mm (Requires confirmation from manual)

Horsepower 500:

Typically in the range of 30-35 HP (Requires confirmation from manual)

Torque 500:

Typically in the range of 30-35 lb-ft (Requires confirmation from manual)

Carburetion Type:

Mikuni or Keihin carburetor (Specific model likely detailed in manual, e.g., Mikuni BST40 or similar)

Fuel Delivery:

Gravity feed or low-pressure fuel pump

Cooling Method:

Liquid-cooled with fan assist

Oil Type:

High-quality 4-stroke ATV oil, likely SAE 10W-40 or 20W-50 (Check manual for exact specification and API service rating)

Ignition Type:

Electronic Ignition (CDI or similar)

Engine Serial Number Location:

Typically stamped on the engine crankcase (Refer to manual for exact location)

🔧 Transmission

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse

Drive System:

Shaft drive to rear differential, driveshaft to front differential (for AWD models)

Clutch System:

CVT (Continuously Variable Transmission) with primary and secondary clutch assemblies.

Gear Reduction:

Integrated reduction gears within the transmission and rear differential.

Transmission Fluid Type:

Specific Polaris PVT fluid or an equivalent high-quality CVT fluid (Refer to manual for exact specification, e.g., Polaris Demand Drive Fluid for front differential)

Transmission Fluid Capacity:

Typically around 1.5 - 2.0 liters for the main transmission and gearbox (Check manual for exact capacity)

📐 Dimensions

Length:

Approximately 83 inches (211 cm) (Check manual for exact spec)

Width:

Approximately 46 inches (117 cm) (Check manual for exact spec)

Height:

Approximately 48 inches (122 cm) (Check manual for exact spec)

Dry Weight:

Approximately 550-600 lbs (250-272 kg) (Check manual for exact spec)

Payload Capacity:

Typically around 200 lbs (90 kg) on racks (Check manual for exact spec)

Towing Capacity:

Typically around 1500 lbs (680 kg) (Check manual for exact spec)

Front Tire Size:

Commonly 25x8-12 or similar (Check manual for exact specification)

Rear Tire Size:

Commonly 25x10-12 or similar (Check manual for exact specification)

Wheel Bolt Pattern:

Not applicable for this type of vehicle; uses hub-mounted wheels.

🛡️ Safety Features

Atv Safety Standards:

Designed to meet relevant ANSI/SVIA standards for ATVs.

Engine Braking:

Standard feature for downhill control.

All Wheel Drive:

Likely available on some models, typically automatically engaging when rear wheels lose traction (ADC - Automatic Differential Lock).

Lighting:

Headlights, taillight, and brake light.

Braking System:

Hydraulic disc brakes on all wheels.

Operator Training:

Polaris strongly recommends reading the owner's manual and taking an ATV safety training course.

💡 Technology Features

Infotainment Features:

Not applicable to this model. Focus is on utility and performance.

Driver Assistance Features:

Automatic Differential Lock (ADC) for enhanced traction in 4WD models.

Connectivity Features:

Not applicable to this model.

🔧 Maintenance

Engine Oil Change:

Typically every 100 hours or annually, whichever comes first (refer to manual for precise interval and operating conditions).

Air Filter Cleaning:

Check every 25 hours, clean or replace as needed, especially in dusty conditions.

Spark Plug Service:

Inspect every 100 hours, replace as recommended.

Clutch Inspection:

Inspect primary and secondary clutches for wear and proper operation periodically, often at 100-hour intervals.

Brake System Check:

Inspect brake pads, fluid levels, and lines regularly.

Engine Oil Specification:

Polaris PS-4 Full Synthetic 4-stroke engine oil, or equivalent SAE 10W-40 or 20W-50 API SG/SH/SJ rated ATV oil.

Coolant Type:

Ethylene glycol based antifreeze/coolant for liquid-cooled engines. Typically a 50/50 mix with distilled water. (Check manual for specific type and capacity).

Brake Fluid Type:

DOT 4 hydraulic brake fluid (Check manual for specific type).

Engine Oil Capacity:

Approximately 2.0-2.5 liters (with filter change) for the 500cc engine (Check manual for exact capacity).

Coolant Capacity:

Approximately 1.5-2.0 liters for the cooling system (Check manual for exact capacity).

Common Issues:

Variations in carburetor tuning affecting starting or running, wear on PVT belt and clutches, potential leaks in cooling system, front differential lock (ADC) sensor issues on some models.

Maintenance Tips:

Regularly inspect and clean the air filter, ensure proper PVT belt tension and condition, keep cooling system clean and topped up, and use correct fluid types.

📚 Vehicle History

Polar Heritage:

Polaris Industries Inc. has a long history in powersports, beginning with snowmobiles and expanding into ATVs and motorcycles. Known for innovation and off-road performance.

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, continuously evolving with advancements in technology, suspension, and engine performance. The 400 and 500 models were popular entry-to-mid-level options.

Production Era:

Early 2000s, a period of significant growth and development for Polaris ATVs.

Manufacturing Location:

Typically manufactured in the United States (e.g., Spirit Lake, Iowa).

🏆 Awards & Recognition

Industry Awards:

The Polaris Sportsman line has historically received positive reviews for its utility, ride comfort, and performance in various publications and by consumers. Specific awards for the 2001 model are not detailed in the product description.