Category:
Entry-level to mid-range utility/recreational ATV.
Target Audience:
Recreational riders, property owners, light utility work.
Competitors:
Competed against models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Bayou/Prairie), Suzuki (KingQuad).
Distinctive Features:
Polaris's well-established independent rear suspension (IRS) on many models, a reputation for comfortable ride quality, and a focus on utility features.
Value For Owner:
Empowers owners to perform detailed maintenance and repairs, saving on labor costs and ensuring the longevity of their ATV.
Engine:
Engine assembly, disassembly, internal components, cooling system, lubrication system, fuel delivery (carburetor/injection), ignition system, exhaust system, starting system.
Drivetrain:
Transmission (CVT), drive belts, clutches (primary and secondary), final drive, driveshafts, differentials, axles, wheel hubs.
Suspension:
Front and rear suspension systems, shocks, springs, A-arms, bushings, steering components.
Brakes:
Hydraulic brake systems, brake calipers, master cylinders, brake lines, brake pads, rotors, parking brake.
Electrical:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting (headlights, taillights, brake lights), starter motor, wiring diagrams, switches, sensors, diagnostic codes.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (specific model dependent, e.g., Mikuni BST40 for 500), fuel pump (if applicable).
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, coolant specifications.
Body And Frame:
Frame inspection and repair, body panels, fenders, racks, seat, handlebars, controls.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug service, coolant flushes, brake fluid service, carburetor cleaning/adjustment.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical system diagnostics, engine performance analysis.
Repair:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems.
Rebuilding:
Complete engine rebuild procedures, transmission rebuild, carburetor overhaul, suspension component refurbishment.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, wiring diagrams, exploded views, part identification.
Depth:
Comprehensive, covering basic maintenance to full engine and transmission overhauls. Includes diagnostic procedures and detailed component-level repair.
Type 400:
Typically a liquid-cooled, 4-stroke, SOHC, single-cylinder engine. Specific displacement around 375cc.
Type 500:
Typically a liquid-cooled, 4-stroke, SOHC, single-cylinder engine. Specific displacement around 499cc.
Horsepower 400 Est:
Approx. 24-28 HP (subject to specific tuning).
Horsepower 500 Est:
Approx. 28-34 HP (subject to specific tuning).
Torque Est:
Torque figures not provided but typical for this class of ATV, favoring low-end grunt for utility.
Carburetion 500:
Often equipped with a Mikuni BST40 or similar carburetor.
Carburetion 400:
Carburetor type varies by sub-model but typically a single-barrel Mikuni.
Type:
CDI (Capacitor Discharge Ignition)
Atv Safety Standards:
Designed to meet industry safety standards for ATVs of its era, but specific crash test ratings are not applicable to ATVs in the same way as passenger vehicles.
Braking System:
Hydraulic disc brakes front and rear.
4Wd Engagement:
On-demand or selectable 4WD (depending on model) for enhanced traction.
Operator Controls:
Ergonomically designed controls for throttle, braking, and gear selection.
Lighting:
Dual headlights, taillight, and brake light for visibility.
Operator Safety Guidelines
Helmet Requirement:
Manual likely emphasizes the importance of wearing an approved helmet, eye protection, and protective clothing.
Oil Change Frequency:
Typically every 100 hours or annually, whichever comes first. Manual will specify exact interval and oil type.
Air Filter Cleaning:
Frequent cleaning or replacement depending on operating conditions, especially in dusty environments. Manual will provide schedule.
Spark Plug Replacement:
Recommended at specific hour intervals or annually. Manual specifies part number and gap.
Brake Fluid Flush:
Recommended every 1-2 years. Manual specifies fluid type (e.g., DOT 3 or DOT 4).
Engine Oil Type:
Likely SAE 10W-40 or 20W-50 motorcycle-specific or ATV oil meeting API SG or higher specifications. Manual is definitive.
Engine Oil Capacity:
Approximately 2.0-2.5 quarts (1.9-2.4 liters), but manual is definitive.
Coolant Type:
Ethylene glycol based antifreeze/coolant. Manual specifies mixture ratio (e.g., 50/50) and type.
Transmission Fluid Type:
Typically a specific gear oil or transmission fluid. Manual is definitive.
Brake Fluid Type:
DOT 3 or DOT 4, depending on the system. Manual is definitive.
Cv Boot Wear:
CV joint boots are susceptible to tearing due to exposure, leading to grease loss and joint damage. Regular inspection recommended.
Carburetor Cleaning:
Carburetors can become clogged over time, especially with fuel sitting, leading to hard starting or poor running. Regular cleaning and proper fuel storage are key.
Drive Belt Wear:
CVT drive belts can wear out and require replacement. Manual will provide inspection intervals and replacement procedures.
Electrical Connections:
Corrosion or loose connections in electrical systems can cause intermittent issues. Manual's wiring diagrams are crucial for diagnosis.
Manufacturer:
Polaris Industries, a long-standing American manufacturer of powersports vehicles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort and versatility, evolving through various engine sizes and feature sets.
Manufacturing Location:
Primarily manufactured in the USA by Polaris.
2005 Market:
2005 was a period of continued growth and refinement in the ATV market, with manufacturers focusing on performance, comfort, and utility features.
