Segment:
Mid-size utility ATV, popular for recreational riding, farm use, and light trail work
Reputation:
Known for its reliable engine, capable suspension, and user-friendly design
Key Competitors 2009:
Honda Foreman/Rancher, Yamaha Grizzly 450/550, Kawasaki Brute Force 300/400, Suzuki KingQuad 400/500
Engine Configuration:
Liquid-cooled, single-cylinder engine, offering good power and smooth operation
Suspension Type:
Independent front and rear suspension for improved ride comfort and handling
Drivetrain Features:
Switchable 2WD/4WD with Polaris's On-Demand AWD system for optimal traction
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with engine braking
Engine:
Detailed coverage of the 499cc liquid-cooled, 4-stroke engine (engine code: P85)
Fuel System:
Carburetion (likely Mikuni BS34), fuel pump, fuel lines, and tank maintenance
Ignition System:
CDI ignition, spark plug specifications, timing adjustments
Cooling System:
Radiator, fan, thermostat, coolant specifications, and bleeding procedures
Exhaust System:
Muffler, header pipe inspection and replacement
Transmission:
PVT (Polaris Variable Transmission) clutch system (primary and secondary), belt inspection and replacement, gearcase lubrication
Drivetrain:
Driveshafts, CV joints, final drive (rear differential), driveshaft U-joints
Suspension:
Front and rear independent suspension, shock absorbers, A-arms, bushings, wheel alignment
Steering:
Handlebar assembly, steering stem, tie rods, steering linkage, power steering (if equipped - likely not standard on this model)
Brakes:
Hydraulic disc brakes (front and rear), brake caliper service, master cylinder, brake lines, fluid specifications (DOT 3/4)
Electrical System:
Battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), electrical connectors
Chassis And Frame:
Frame inspection, mounting points, body panels, fenders, racks
Wheels And Tires:
Tire pressures, wheel lug nut torque, tire replacement
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustments (if applicable - usually shaft drive), lubrication points
Engine Overhaul:
Top-end rebuild (cylinder head, piston, rings), bottom-end inspection and repair (crankshaft, bearings), valve adjustments
Transmission Service:
Clutch inspection, belt replacement, gearcase fluid change, potential rebuild procedures for the transmission components
Brake System Repair:
Bleeding, pad replacement, caliper rebuilding, master cylinder service
Electrical Troubleshooting:
Wiring diagrams, diagnostic procedures for charging system, starter, lighting faults
Suspension Adjustment And Repair:
Shock adjustments, bushing replacement, alignment procedures
Steering System Repair:
Tie rod end replacement, steering stem bearing service
Troubleshooting Guides:
Diagnostic charts for common starting issues, performance problems, and system failures
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Depth:
Extensive, covering both routine maintenance and complete mechanical and electrical overhauls
Diagnostics:
Includes detailed diagnostic procedures and troubleshooting flowcharts
Special Tools:
Lists required special tools for specific repair procedures
Torque Specifications:
Provides precise torque values for critical fasteners
Clearances:
Specifies critical component clearances (e.g., valve lash, bearing clearances)
Engine Type:
4-stroke, liquid-cooled, SOHC, 4-valve, single-cylinder
Displacement:
499cc (30.4 cu. in.)
Bore X Stroke:
92 mm x 75 mm (3.62 in. x 2.95 in.)
Compression Ratio:
10.4:1
Carburetor:
Mikuni BS34 (likely)
Horsepower Estimated:
Approx. 36-38 HP (at 6000 RPM)
Torque Estimated:
Approx. 30-32 lb-ft (at 4500 RPM)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Capacity:
3.25 US gallons (12.3 L)
Oil Type:
SAE 20W-50 API SG or higher (check manual for exact specification)
Oil Capacity:
Approx. 2.1 US quarts (2.0 L) with filter change
Spark Plug Type:
NGK CR7E (verify with manual)
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first (check manual for specific recommendations)
Air Filter Cleaning:
Every 25 hours, or more frequently in dusty conditions
Spark Plug Inspection:
Every 100 hours or 12 months
Transmission Fluid Change:
Every 100 hours or 12 months (front and rear gearcases)
Pvt Belt Inspection:
Every 50 hours or 6 months (check for wear and proper tension)
Engine Oil:
SAE 20W-50 API SG or higher
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant:
Ethylene glycol-based antifreeze mixed 50/50 with distilled water (ensure freeze protection)
Gearcase Oil:
Polaris Demand Drive Fluid or suitable synthetic gear oil
Common Wear Items:
PVT belt wear, suspension bushings, tie rod ends, wheel bearings
Potential Failures:
Charging system components (stator, regulator/rectifier) can be prone to failure; early models might have carburetor tuning issues
Typical Repairs:
Clutch belt replacement, suspension linkage rebuild, brake caliper service, electrical diagnostics
Polar Heritage:
Polaris Industries Inc. has been a major player in the powersports industry since its founding in 1954, known for innovation in ATVs and snowmobiles.
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris, evolving from simpler models to more powerful and feature-rich ATVs. The 500cc class has consistently been a popular offering.
Key Upgrades Prior To 2009:
Introduction of independent rear suspension, fuel injection (though this model is carbureted), and Polaris's On-Demand AWD system were significant advancements in preceding years.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA
